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BUREAU OF INDIAN STANDARDS MECHANICAL ENGINEERING DEPARTMENT

Please correspond at Phone: 23232509; Fax: + 91 11 23232509; Email: [email protected]

DOCUMENT DESPATCH ADVICE

Continuous Bulk Conveying, Elevating, Hoisting, Aerial Ropeways and related Equipment

Sectional Committee, MED 06

----------------------------------------------------------------------------------------------------------------------------- --

1) All Members of Mechanical Engineering Division Council

2) All Members of Continuous Bulk Conveying, Elevating, Hoisting, Aerial Ropeways and related Equipment Sectional Committee, MED 06 3) All other interested members Dear Sir(s),

Please find enclosed the following documents:

Doc No. Title

MED 06 (1286)

WC Code of recommended practice for continuous mechanical

handling equipments-safety : Part 1- General Information

[Second revision of IS 7155 part-1]

ICS 53.040.20

MED 06 (1287)

WC Idler and Idler sets for belt conveyor – Specification

(Second Revision of IS 8598)

ICS 53.040.01

Kindly examine the draft standards and forward your views, stating any difficulties which you are likely to experience in your business or profession, if they are finally adopted as National Standards.

Last date for comments: 30.11.2015.

Comments, if any, may please be made in the format as given overleaf and mailed to the

undersigned at the above address.

In case no comments are received or comments received are of editorial nature, you will kindly permit us to presume your approval for the above document as finalized. However, in case of comments of technical in nature are received then it may be finalized either in consultation with the Chairman, Sectional Committee or referred to the Sectional committee for further necessary action if so desired by the Chairman, Sectional Committee.

The document is also hosted on BIS website [email protected]

Thanking you, Yours faithfully,

-sd-

Encl.: As above (T.V. Singh)

Sc `F’ & Head (MED)

DRAFT IN WIDE

CIRCULATION Ref. Date

MED 06 /T- 32 & 18 18/09/2015

mailto:[email protected]

http://www.iso.org/iso/home/store/catalogue_ics/catalogue_ics_browse.htm?ICS1=53&ICS2=040&ICS3=20&&published=on


भारतीय मानक यर

यारिक इजीननयररग विभाग

फ न पर अन प कर: 23232509; फस: + 91 11 23232509; ईमल: [email protected]

यापक पररचालन मस दा

सतत बक सदश, ऊपर उठान, उथापन, हिाई र पि और सबधित उपकरण की विषय सममनत, एमईडी 6 रवषनत :

1. य रिक इजिनियरी विभाग परर षद क सभी सद य

2. सतत बक सदश, ऊपर उठाि, उथापि, हिाई र पि और सबधित उपकरण की विषय समिनत, एिईडी 06

क सभी सद य

3.धि रखि िाल अ य निकाय

िह दय,

नि िमलिखत िािक क िस द सल ि ह:

रलख स या शीषषक

एिईडी 06 (1286) निरतर यारिक ह:डमलग उपकरण की सरषा की मसफाररश भाग 1- सािाय सििा [

आई एस 7155 (भाग 1) का दसरा पिरीषण ] (आई सी एस स या 53.040.20 (

एिईडी 06 (1287) आइडलर और आइडलर सट क मलए कियर बट – विमशजटट (आई एस 8598 का दसरा पिरीषण) (आई सी एस स या 53.040.01 (

कपया इि िस द का अिल कि कर और अपिी स िनतया यह बतात हए भि िक अतत यिद य िािक राट रीय िािक क प ि िकामशत ह िाो त इि पर अिल करि ि आपक यिसाय अथिा कार बार ि या किठिाईय आ सकती ह: ।

स िनतया भिि की अजति नतधथ 30.11.2015

स िनत यिद क ई ह त कपया अि ह ताषरी क उपरमलिखत पत पर सल ि फ िटट ि भल या ईिल कर द ।

यिद क ई स िनत िा‍ त िही ह ती ह: अथिा स िनत ि किल भाषा सबिी ििट हई त उपर त िलख क यथाित अनति प िदया िायगा । यिद क ई स िनत तकिीकी िकनत की हई त विषय समिनत क अ यष क परािशट स अथिा उिकी इ‍ ा पर आग की कायटिाही क मलए विषय समिनत क भि िाि क बाद िलख क अनति प द िदया िाएगा ।

यह िलख भारतीय िािक यर की िबसाइट [email protected] पर भी उपल ि ह ।

ि यिाद, भिदीय, -एसडी-

(टी. िी. मसह )

िञाननक `एफ’ एि रमख (एमईडी) सर न :उपरमलरखत

सदभष ददनाक

एमईडी 06/टी – 32 एि 18 18/09/2015


MED 06 (1286) WC September 2015

1

Draft for Comments Only

Draft Indian Standard

CODE OF RECOMMENDED PRACTICE FOR CONTINUOUS MECHANICAL

HANDLING EQUIPMENTS-SAFETY - PART 1- GENERAL INFORMATION

[Second Revision of IS 7155 Part-1]

ICS 53.040.20

Not to be reproduced without the permission of Last date for receipt of

BIS or used as a STANDARD comments is: 30.11.2015

FOREWORD

(Adoption clause to be added later on).

This standard was first published in year 1974 and first revision was made in year 1986. This

revision has been undertaken to incorporate changes based on the experience gained in the use of

Conveyor.

The major changes in the revision are:

Continuous mechanical handling equipments used for transportation of bulk materials

or unit loads have been included.

Lighting and Air Ventilation system included

For the purpose of deciding whether a particular requirement of this code is complied with the

final value, observed or calculated, expressing the results of a test or analysis, shall be rounded

off in accordance with IS 2:1960 ‘Rules for rounding off numerical values (revised)’. The number of significant places retained in the rounded off value should be the same as that of the

specified value in this standard

http://www.iso.org/iso/home/store/catalogue_ics/catalogue_ics_browse.htm?ICS1=53&ICS2=040&ICS3=20&&published=on


2

1 SCOPE

This Standard provides general information relating to the recommended practice to be adopted

for safe use of continuous mechanical handling equipments (temporary or permanent) used for

transportation of bulk materials or unit load.

1.1 This Standard does not apply to industrial trucks, tractors or trailers, tiering machines, cranes,

hoists, skip hoists, monorails, power and hand shovels, power scoops, bucket drag lines, platform

elevators designed to carry passengers or the elevator operator, moving stairways and highway or

rail vehicles, or conveyors specifically designed for the movement of passengers.

2. REFERENCE

The Indian Standards as listed in Appendix A and Appendix B contain provisions which through

reference in the text, constitute provision of this standard. At the time of publication, the editions

indicated were valid. All standards are subject to revision, and parties to agreements based on

this standard are encouraged to investigate the possibility of applying the most recent editions of

the standards indicated in Appendix A and Appendix B.

3. TERMINOLOGY

3.1 For the purpose of this code, the following definitions, in addition to those given in IS

4240:1984 Glossary of conveyor terms and definitions (first revision) shall apply.

3.2 Continuous mechanical handling system-An installation of two or more mechanical handling

equipments which transport or transfer loads from one equipment to another and whose control is

integrated.

3.3 Normal Working Conditions - Specified conditions as agreed by the interested parties for

the use of continuous mechanical handling equipment.

3.3.1 These normal working conditions will either be defined by the customer or customer's

consultant and agreed with the manufacturer at the time of placement of the purchase order, or

defined or specified for the equipment in the manufacturer's documents, which are approved or

accepted by customer.

3.4 Personnel - Persons essential to the use (the operation) of the continuous mechanical

handling equipment itself and persons legitimately in the vicinity.

4. MATERIALS

4.1 Unless otherwise specified all materials used in the construction and operation of a conveyor

and its supporting structure shall comply with the requirements of relevant Indian Standards

where available. A list of such Indian Standards for guidance is given in Appendix A. Materials

equivalent to or superior to those specified may be used subject to agreement between the

manufacturer and the user.


3

5. GENERAL INFORMATION

5.1 Stages -The safety requirements of the conveyors of various types may be divide into three

stages as follows:

a) Construction stage (design and manufacture),

b) Installation stage (layout, erection and entry into service); and

c) Utilization stage (operation and maintenance).

5.1.1 The safety requirements during construction stage shall be those to be taken care of during

the design and manufacture of the conveyor system, equipments and machinery.

5.1.2 The safety requirements during installation stage shall be those to be taken care of during

layout, erection and entry into service of the conveyor system, equipments and machinery.

5.1.3 The safety requirements during utilization stage shall be those to be taken care of during

operation and maintenance of the conveyor systems, equipments and machinery.

5.2 Lighting - Suitable lighting of conveyor systems, equipments and machinery shall be

provided. For guidance recommendations of IS 3646 ‘Code of practice for interior illumination’ in following parts may be referred:

(Part 1):1992 Principles of good lighting and aspects of design

(Part 2):1966 Schedule for values of illumination and glare index

(Part 3):1968 Calculation of coefficients of utilization by the BZ method

5.2.1 Permanent lighting shall be installed in tunnel, RCC Gallery and pits with switch board

located convenient to the entrance

5.2.2 Electric outlets for hand lamps shall be provided at convenient locations.

5.2.3 The lamps/lights shall be cleaned regularly.

5.2.4 Air Ventilation system shall be provided in tunnel, pits, RCC Gallery as per requirement.

5.3 Electrical Equipment - Electrical equipment shall be installed and maintained to meet the

statutory requirements. For guidance following Indian Standards may be referred:

a) IS 732 - Code of practice for electrical wiring installations (Third Revision)

b) IS 4051- Code of practice for installation and maintenance of electrical equipment in mines;

c) IS 5571- Guide for Selection and installation of Electrical Equipment for Hazardous Areas

(other than mines) (third revision);

d) IS 5572 - Classification of hazardous areas (other than mines) having flammable gases and

vapours for electrical installation (third revision); and

5.4 Fire Protection - Adequate fire protection facilities shall be provided and shall be as per the

approval of the statutory authority. For guidance following Indian Standards may be referred:


4

a) IS 1641- Code of practice for fire safety of buildings (general): General principles of fire

grading and classification (Second Revision)

b) IS 1642 - Fire safety of buildings (general): Details of construction - Code of practice (Second

Revision)

c) IS 1643 - Fire Safety of Buildings (General): Exposure Hazard — Code of Practice (Second

Revision)

d) IS 1644 - Fire Safety of Buildings (General): Exit Requirements and Personal Hazard — Code

of Practice (Second Revision)

e) IS 3034 - Fire Safety of Industrial Buildings: Electrical Generating and Distributing Stations -

Code of Practice (Second Revision)

5.5 Dust and Fumes - Where dust or fumes may become a hazard, means shall be taken to

prevent injury to persons. The design of the system shall be such as to prevent or control the

emission of dust and fumes.

5.6 Static Charge/Electricity -- It is known that continuous rotation and friction of non-metallic

components in a conveyor system produces a lot of static electricity. For normal run-off mine

handling plants for coal, iron, limestone, etc, the accumulated static charge may not pose much

of a problem. However, for special application of conveyors, which carry explosive dusts and

compounds, limiting the accumulated static charge/electricity in a conveying system is extremely

important.

5.6.1 Where accumulated static charge/electricity is considered important, the limit of such a

charge shall be as agreed to between the user and the manufacturer.

5.7 List of Indian Standards on conveyors, vertical hoists, bulk elevators and bulk handling

equipment is given in Appendix B for information.


5

APPENDIX A

(Clause 4.1)

INDIAN STANDARD SPECIFICATIONS ON MATERIALS

A-l. Structural Steel

IS 277:2003 Specification for Galvanized Steel Sheets (Plain & Corrugated)

IS 808:1989 Specification for rolled steel beam, channel and angle sections (revised)

IS 811:1987 Specification for cold formed light gauge structural steel sections (revised)

IS 1161:l 998 Specification for steel tubes for structural purposes (third revision)

IS 1239 Specification for mild steel tubes, tubulars and other wrought steel fittings:

IS:1239 (Part-1) :2004 Part-1 Mild Steel tubes (Sixth Revision)

IS 1239 Specification for mild steel tubes, tubulars and other wrought steel fittings:

(Part 2):2011 Part 2 Mild steel tubulars and other wrought steel pipe fittings (third revision)

IS 1252:1991 Specification for rolled steel sections bulb angle

IS 2062:2011 Specification for Hot Rolled Medium and High Tensile Structural Steel (seventh

revision)

IS 3039:1988 Specification for structural steels for construction of hulls of ships (first revision)

IS 3443:1980 Specification for grane rail sections (first revision)

IS 3601:2006 Specification for steel tubes for mechanical and general engineering purposes

( first revision )

IS 3954:1991 Specification for hot rolled steel channel sections for general engineering

purposes

IS 4923:l 997 Specification for hollow steel sections for structural use (first revision)

A-2. Forgings and Castings

IS 210:2009 Specification for grey iron castings (third revision)

IS 276:2000 Specification for Austenitic-Manganese Steel Castings

IS 1030:1998 Specification for carbon steel castings for general engineering purposes

(third revision)

IS 1865:1991 Specification for iron castings with spheroidal or nodular graphite

revision)

IS 2004 :l 991 Specification for carbon steel forgings for general engineering purposes

revision)

IS 14329:l 995 Specification for Malleable Iron Castings

IS 4367:1991 Specification for alloy and tool steel forgings for general industrial use

IS 4771:I 985 Specification for abrasion-resistant iron castings (second revision )

IS 4896:l 992 Specification for one :percent chromium steel castings for resistance to

(first revision )

A-3. Rivets

IS 1929:1982 Specification for hot forged steel rivets for hot closing (12 to 36 mm diameter)

(first revision )

IS 2998:l 982 Specification for cold forged steel rivets for cold closing (1 to 16 mm diameter)

(first revision )

A-4. Bolts

IS 1363 Specification for hexagon head bolts, screws and nuts of product grade C:


6

(Part I):2002 Hexagon head bolts (size range M 5 to M 36) (second revision)

(Part 2):2002 Hexagon head screws (size range M 5 to M 36) (second revision)

(Part 3):2002 Hexagon nuts (size range M 5 to M 36) (second revision)

IS 1364 Specification for hexagon head bolts, screws and nuts of product grades A and B:

(Part I):2002 Hexagon head bolts (size range M 3 to M 36) (second revision)

(Part 2):2002 Hexagon screws (size range M 3 to M 36) (second revision)

IS 2585:2006 Specification for black square bolts and nuts (diameter range 6 to 39 mm)

black square screws (diameter range 6 to 24 mm) (first revision)

A-5. Conveyor Belts

IS 1891 Rubber conveyor and elevator textile belting:

(Part I) :1994 General purpose belting ,(third revision)

(Part 2) :l 994 Heat-resistant belting (second revision)

(Part 3) :1988 Oil-resistant belting (second revision)

(Part 4) :1978 Hygienic belting

(Part-5) :1993 Fire resistance Belting for surface applications.

IS 3181:l 992 Specification for fire resistant conveyor belting for underground use in coal mines

(first revision)

A-6. Chain

IS 2403:1991 Specification for transmission steel roller chains and chain wheels (first revision)

IS 3542:l 980 Specification for extended pitch transmission precision roller chains and chain

wheels (first revision)

IS 3560:1980 Specification for short pitch transmission precision bush chains and chain wheels

(first revision)

IS 3948:1986 Specification for calibrated high tensile steel (round link) chain (electric butt

welded) for chain conveyors and coal ploughs used in mines (first revision)

IS 6834 Specification for conveyor chains, chain -wheels and attachments

(Part I):1 973 Chains

,(Part 2):1976 Chain - wheels

(Part 3):1976 Attachments

A-7. Gears

IS 2535:2004 (Part-1) Specification for Cylindrical Gears for standard basic rack tooth profile

(Third revision)

IS 2535:2004 (Part-2) Specification for Cylindrical Gears for module. (Third revision)

IS 3734:1983 Dimensions for worm gearing (first revision)

IS 5037:2004 (Part-1) Specification for basic rack of straight bevel gears for general engineering

& heavy engineering (First revision)

IS:5037:2004 (Part-2) Specification for Module and diametric pitches of straight bevel gears for

general engineering & heavy engineering (First revision)

IS:7403:1974 Code of practice for selection of standard worm & helical gearboxes.

A-8. Wire Ropes

IS 1856:2005 Specification for steel wire ropes for haulage purposes (second revision)


7

IS 2266:2002 Specification for steel wire ropes for general engineering purposes (second

revision)

A-9. Concrete

IS 456:2000 Code of practice for plain and reinforced concrete (third revision )

A-10. Lighting Purposes

IS 3646 Code of practice for interior illumination:

(Part 1):1992 Principles of good lighting and aspects of design

(Part 2):1966 Schedule for values of illumination and glare index

(Part 3):1968 Calculation of coefficients of utilization by the BZ method

Note - Updated information regarding Indian Standards is available on BIS website

www.bis.org.in


8

APPENDIX B

(Clause 5.7)

INDIAN STANDARDS ON CONVEYORS, HOISTS AND RELATED

MATERIAL HANDLING EQUIPMENT

IS 4240: I984 Glossary of conveyor terms and definitions (first revision)

IS 4776 Specification for troughed belt conveyors:

(Part I):1977 Surface installation (first revision)

(Part 2):1977 Troughed belt conveyors for underground installation

IS 5228:2003 Code of practice for construction of continuous movement monocable

rope ways with fixed grips intended for transportation of passengers

IS 5229:l 998 Code of practice for construction of continuous movement monocable

ropeways with automatic grips intended for transportation of passengers

IS 5230:2003

IS 5563:1985

IS 5895:1985

IS 5972:1970

IS 6832:1985

IS 6833:l 973

IS 6930:1973

IS 7054:1973

IS 7167:l 974

IS 7423:1974

IS 7439:1974

IS 7465:1974

IS 7649:1975

IS 8531:I 986

IS 8597:1977

IS 8598:1977

IS 8599:1977

IS 8646:1977

IS 8647:1977

IS 8723:1978

IS 8730:1997

IS 9047

(Part I):1 978

(Part 2):l 980

(Part 3):l 983

.(Part 4):l 983

Code of practice for construction of continuous to-and-fro movement bi-

cable ropeways intended for transportation of passengers

Specification for screw conveyors for industrial use (first revision)

Specification for steel roller conveyors (first revision)

Glossary of pneumatic and hydraulic conveying terms and definitions

Specification for fixing screws and fixing washers for buckets for bucket

elevators (first revision)

Specification for bucket elevators

Dimensions for fixing arrangements of buckets for bucket elevators

Specification for casing for bucket elevators

Code for selection and use of bucket elevators

Dimensions for apron conveyors

Dimensions for aeroslides

Specification for portable and mobile troughed belt conveyors

Glossary of terms used in connection with aerial ropeways and cableways

Specification for pulleys for belt conveyors (first revision)

Specification for flat belt conveyors

Specification for idlers and idler sets for belt conveyors

Recommendations for selection of apron conveyors

Specification for scraper (flight) conveyors

Specification for design criteria for pneumatic conveying systems

Dimensions for vibrating conveyors and feeders with rectangular or

trapezoidal trough

Classification of bulk materials handled by continuous mechanical

handling equipment

Specification for data sheet for aerial ropeways and cableways:

Data to be supplied by intending purchaser for aerial system for

transportation of goods


transportation of passengers, surface


transportation of passengers, under ground


transportation of goods, under ground


9

(Part 6):l 980

IS 9228:1979

IS 9413:1980

IS 9454:1980

IS 9706:1980

IS 9776:1981

IS 9777:1981

IS 10095:1982 IS/ISO 6750:2005 IS 10303:1982

IS 10443:I 983

IS 10463

(Part 2):1985

(Part 6):1983

IS 10464:1983

IS 10678:I 983

IS 10689:1983

IS/ISO 2867:2006

IS 10856:l 984

IS 10859:1984


transportation of forestry products

Specification for mono seat chairs for chairlifts used in winter sports

Specification for rope guide rollers for haulage ropes for bicable aerial

ropeways for transportation of goods

Specification for bicable load carriers

Code of practice for the construction of aerial ropeways for the

transportation of material

Specification for data sheet for selection of weighing-cum-tipping/bag

filling machines for bulk handling

Specification for data sheet for weigh bridges for bulk handing equipment

Guidelines for selection of tipplers for broad gauge open railway wagons

Earth-moving machinery - operator's manual - Content and format

Code of practice for preservation and storage of earth moving equipment

Specification for data sheet for selection of marine loading arms

Glossary of terms for bulk handling equipment:

Stacking, loading and reclaiming equipment

Cyclic loose bulk handling equipment (non-stationary)

Specification for data sheet for selection of wagon puller/pusher

Specification for data sheet for design/selection of vacuum producer

Specification for minimum dimensions for access openings on earth-

moving machinery

Earth-moving machinery - Access systems

Specification for volumetric rating of elevating scrapers

Specification for volumetric rating of dumper bodies

IS 732:1989 Code of practice for electrical wiring installations (Third Revision)

IS 4051:1967 Code of practice for installation and maintenance of electrical equipment

in mines;

IS 5571:2009 Guide for Selection and installation of Electrical Equipment for Hazardous

Areas (other than mines) (third revision);

IS 5572:2009 Classification of hazardous areas (other than mines) having flammable

gases and vapours for electrical installation (third revision);

IS 1641:2013 Code of practice for fire safety of buildings (general): General principles

of fire grading and classification (Second Revision)

IS 1642:2013 Fire safety of buildings (general): Details of construction - Code of

practice (Second Revision)

IS 1643:2013 Fire Safety of Buildings (General): Exposure Hazard — Code of Practice

(Second Revision)

IS 1644:2013 Fire Safety of Buildings (General): Exit Requirements and Personal

Hazard — Code of Practice (Second Revision)

e) IS 3034:1993 Fire Safety of Industrial Buildings: Electrical Generating and Distributing

Stations - Code of Practice (Second Revision)

Note - Updated information about these Indian Standards is available on BIS website:

www.bis.org.in

MED 06(1287)WC September 2015

1

Draft for Comments Only

Draft Indian Standard

IDLER AND IDLER SETS FOR BELT CONVEYOR - SPECIFICATION

(Second Revision of IS 8598)

ICS 53.040.01

Not to be reproduced without the permission of Last date for receipt of

BIS or used as a STANDARD comments is: 15 Feb 2014

FOREWORD

(Adoption clause to be added later on).

This standard was first published in year 1977 and first revision was made in year 1987. This

revision has been undertaken to incorporate a number of changes based on the experience gained

in the use of idler rollers and idler sets.

The major changes in the revision are:

- Standard has been modified to include conveyors operating at a speed up to 5 m/s.

- Classification of Idlers has been included.

- Figures have been modified

- Values in Table have been modified.

− Scope- Details incorporated as per present design practice/norms.

− Terminology-Revised details are incorporated.

− Details dimensions with Table and Figure are included.

− Requirement-Details are included.

− Idlers run out norms included.

For the purpose of deciding whether a particular requirement of this code is complied with the

final value, observed or calculated, expressing the results of a test or analysis, shall be rounded

off in accordance with IS 2:1960 ‘Rules for rounding off numerical values (revised)’. The number of significant places retained in the rounded off value should be the same as that of the

specified value in this standard


2

1. SCOPE

This Indian Standard covers the requirement of Carrying Idlers with their arrangement of three

rollers and Return Idlers with one roller to three Rollers for troughed belt conveyors operating

at a speed up to 5 m/s.

1.1 It does not cover idlers and idler sets for portable conveyors, mobile conveyors and

rolling conveyors, and also Garland, catenary and Impact idlers.

2. REFERENCE

The Indian Standards as listed in Annex A contain provisions which through reference in the

text, constitute provision of this standard. At the time of publication, the editions indicated were

valid. All standards are subject to revision, and parties to agreements based on this standard are

encouraged to investigate the possibility of applying the most recent editions of the Standards

indicated in Annex A.

3. TERMINOLOGY

In addition to the terminology specified in IS 4240, the following shall also apply:

3.1 Roller- Rotating parts of Idlers, which support the belt.

3.2 Frame-structural parts in which, rollers are mounted.

3.3 Troughing Angle (λ)- Angle of the axis of side rollers of idlers from the horizontal.

3.4 Idler Vertical clearance (m)- The vertical clearance of the bottom periphery of central

roller and the top of the transom or any structural frame, nearest to roller.

4 CLASSIFICATION OF IDLERS:

Idlers for Troughed Belt conveyors are of following types:.

a) Carrying Idlers inline, of equal rollers length, supporting the carrying belt.

a1) Carrying idlers inline, of unequal rollers length, supporting the carrying belt.

b) Carrying Idlers of staggered, of equal rollers length, supporting carrying belt.

b1) Carrying idlers staggered, of unequal rollers length, supporting the carrying belt

c) Return Idlers of one roller, supporting return belt.

d) Return Idlers of two rollers, supporting return belt

e)Return Idlers of three rollers inline, supporting return belt.


3

e1) Return idlers of three rollers staggered, supporting return belt

4.1 Refer IS 11592 for selection of idler rollers.

5. DIMENSION

5.1 Idler Roller outer diameter (d1)- The outer diameter of carrying and return roller as

shown in Fig 1 shall be selected from the Table-1.

Ød1

l

FIG 1-Typical Idler Roller

TABLE 1

Carrying and Return Roller of Idlers-Diameters in mm

Roller of

carrying

Idlers

only

63.5 76.1 88.9 101.

6

108 114.

3

127 133 139.

7

152.4 159 168.3 193.

7

219.1

5.2 Lengths-Rollers of Idlers - Figures 2, 3 & 4 shows rollers for 1 piece, 2 piece & 3 piece

idlers respectively. Table 2 shows the length of rollers for carrying/return idlers of troughed Belt

Conveyor.


4

Ød1

l

Figure-2

ll

Figure-3

l

ll


5

Figure-4

TABLE 2

Belt width

b-mm

Return Roller length (l) in mm

One Piece Two piece Three piece

400 500 250 160

500 600 315 200

650 750 380 250

800 950 465 315

1000 1150 600 380

1200 1400 700 465

1400 1600 800 530

1500 1700 850 565

1600 1800 900 600

1800 2000 1000 670

2000 2200 1100 750

2200 2500 1250 800

2400 2800 1400 900

Roller lengths for unequal rollers shall be as agreed between the purchaser and the manufacturer.

5.3 Carrying/Return Idler-Mounting Dimension shall be as shown in figure-5 and 6 and

Table-3.

m

e1

e2

l1

l2

BELT WIDTH 'B'

BELT WIDTH 'B'

SLOTS 'SL'

FOR BOLT 'ØD'

s3

s1

Ød

1

ØD

+2

Min

.

Figure-5-Carrying and One piece Return Idler


6

m

e2

l1

l2

BELT WIDTH 'B'

SLOTS 'SL'

FOR BOLT 'ØD'

s2

Figure-6-Two piece Return Idler

TABLE 3

Belt

width

'B' mm

l1 l2 e1

e2

D s1 s2 s3 1pc.

Return

idler

2pc.

Return

idler

400 690 755 200 65 100 M12 50 40 35

500 790 855 200 65 100 M12 50 40 40

650 940 1000 200 65 100 M12 50 55 50

800 1090 1150 200 65 100 M12 75 65 70

1000 1290 1350 200 65 100 M12 75 75 70

1200 1490 1555 200 65 100 M16 100 100 100

1400 1690 1755 200 65 100 M16 100 100 100

1500 1790 1855 200 65 100 M16 100 100 100

1600 1900 1965 200 65 100 M16 100 100 100

1800 2100 2165 200 65 100 M20 100 100 100

2000 2300 2365 200 65 100 M20 100 100 100

2200 2550 2615 200 100 100 M20 150 150 100

2400 2750 2815 200 100 100 M20 200 200 150

5.3.1 Slots for mounting Bolts(SL)

Slots for mounting bolts of diameter D shall be width D+2 mm, Min and 25 mm, Min

long in the longitudinal direction along the direction of conveyor ( see figure-5 and 6)

5.3.2 Clearance dimension requirement (m)

The Clearance requirement beneath center roller and both side of carrying rollers(see

figure-5) shall be as given in Table-4

Table 4


7

Diameter of roller for Carrying

idler 'd1' (mm) ≤ 127

127 < d1 ≤ 168.3

≤ 193.7 ≤ 219.1

Minimum clearance 'm' (mm) 30 40 50 60

The clearance height for 1 piece Return roller shall be as agreed between the purchaser and the

manufacturer.

5.4 Spindle Ends

5.4.1 Type A spindle without added end cap

m n

Figure-7

All dimensions in millimeters.

Table 5

d2 d3 (Min.) b1 m n*

20 20 14 4 9

25 25 18 4 9

30 30 22 4 9

35 35 28 4 9

40 40 32 4 9

45 45 38 4 9

*For return idler n+10 is permissible.


8

5.4.2 Type B spindle without added end cap

m n p

A

Figure-8

All dimensions in millimeters.

Table 6

d2 d3 b1 m n p

20 20 14 4 9 5

25 25 18 4 9 5

30 30 22 4 9 5

35 35 28 4 9 5

40 40 32 4 9 5

45 45 38 4 9 5

5.4.3 Type C Spindle end with added end cap

m n

Figure-9


9

Table 7

d2 d3 b1 m n

35 20 28 4 10

40 25 32 4 12

45 30 38 4 12

5.4.4 Type D spindle end with added end cap

m n p

A

A

A-A

Figure-10

Table 8

d2 d3 b1 m n p

35 20 28 4 9 5

40 25 32 4 9 5

45 30 38 4 9 5

5.4.5 Idlers with one shot lubrication may have special shaft ends suitable for the purpose

5.4.6 Impact idlers and troughing training idlers rollers shall have spindle ends similar to those

of troughing idlers rollers and shall conform to 4.4.1 to 4.4.4. The return training idlers rollers

shall have ends similar to return idlers rollers.

6 REQUIREMENTS

6.1 Troughing Angle (λ)- The value of troughing angle shall be selected from those given

below for all standard widths of belt conveyor.

10° 15° 20° 25° 30° 35° 40° 45°

Note 1-The designer shall satisfy himself that belt construction shall trough adequately

on troughing idlers


10

6.2 Troughing Angle of Return Idlers

6.2.1 Two Piece Return Idlers-The value of troughing angle of rollers of return idlers shall be

selected 10°,15°,20°

6.2.2 Three Piece Return Idlers-The value of troughing angle of rollers of return idlers shall be

selected 10°,15°,20°,30°

6.3 Angle of Tilt (ψ) of side rollers of idlers-Shall be chosen as function of troughing angle

(λ) and the belt speed, and shall be as small as practicable and in any case shall not be more than

3°(see Fig.11). The angle of tilt(ψ) of side rollers of idlers shall be in the direction of belt run for

the unidirectional conveyors and it shall be zero degree for reversible conveyors.

6.3.1 It is not obligatory to provide angle of tilt(ψ) unless specifically desired by the purchaser.

Angle of tilt on side rollers of idlers may be eliminated by using training idlers or side guide

rollers.

.

. Angleof tilt

Direction of Belt run

Tro

ughin

gA

ngle

Figure-11

6.4 Arrangement of in-line and staggered carrying rollers of idlers.

6.4.1 Troughing carrying idler sets built up from three rollers may be arranged with rollers in-

line or staggered as shown in the plan view in Fig-12


11

CL ofBelt

CL ofBelt

Direction of Belt run

.

This Dimension shall not be

Less than Roller diameter

IN - LINE STAGGERED

Figure-12

6.4.1.1 When staggered, the displacement of the axis of the center roller from the adjacent axis of

the side rollers shall not be less than the diameter of rollers.

6.4.2 Staggered carrying 3 roller sets shall be arranged with adjacent ends of side rollers and

center roller overlapping by minimum of 10 mm when measured as indicated in Fig-

13.For 3 roll in staggered transition.

CENTER ROLLER

SIDEROLLER

INTERSECTION OF BELTCONTACT SURFACES

10 mm Maximum Gap

IN - LINE

CENTER ROLLER

SIDEROLLER

INTERSECTION OF BELTCONTACT SURFACES

10 mm MinimumOverlap

STAGGERED

Figure-13

6.4.3 The gap between the adjacent ends of the center and side rollers of an in-line 3-roll set

shall not be greater than 10mm when measured as indicated in figure-13. For 3-roll in-

line transition idlers, the gap between rollers can be increased as agreed between the

purchaser and the manufacturer.


12

6.4.3.1 Whenever it is not feasible to achieve this gap of 10 mm due to end details of idlers, in

such case, roller diameter up to and including 108 mm, the permissible gap between rolls may be

increased to 23 mm.

6.5 Run-out-- The idler roller diameter, measured by a dial test indicator at any point along

its length when rotated on its own bearing shall not exceed the total indicator reading in respect

to belt speed as indicated in Table:9

Table 9

Belt Speed-v (mtr/sec)

Roller length-l (mm)

≤ 3 3 > v ≤

4

4 > v ≤ 5

Run out in mm

≥ 750 1.4 1.0 0.8

750 > l ≤ 1200 1.6 1.2 1.0

< 1200 1.8 1.4 1.2

6.6 Idler Bearing -Unless the purchaser specifies a longer minimum rated life, the minimum

design rated life for the idler bearings shall be 25000 hour for bearings lubricated for life time as

well as intermittently lubricated bearings. Seize-resistant ball bearing for idlers shall be

preferable (if available).

6.7 Steel Tubes used in manufacture of idlers rollers and idler sets shall conform to IS 9295.

6.8 Test, process of construction, specific materials and other requirements in view of the

application, environmental and meteorological condition of use of the idlers/idlers set shall be as

agreed to between the manufacturer and purchaser.

7. DESIGNATION OF IDLER SET SHAPE OF IDLERS.

7.1 Designation of idler roller-An idler roller diameter (d1) of 133 mm and roll length (l) of

1000 mm, with spindle type A with (d2) of 25mm shall be designated as:

Idler roller 133 x 1000 Ax25 IS 8598.

7.2 Designation of Idler set-An carrying idler set of 3 piece design, 35 degree troughing

angle, diameter d1 of 133 mm, for 1000 mm belt width with spindle end of type A with d2 of

20 mm shall be designated as:

Idler 133 x 3P x 35°x1000BWxAx20 IS 8598

Note: For Idler roller or Idler set having special specifications than details descriptions shall be

followed.

8 MARKING-The idlers shall be marked with following:

i. Roller diameter x Roller length x Spindle diameter at bearing


13

ii. Drawing number

iii. Manufacturer's name

iv. Quarter & year of manufacturing

8.2 BIS Certification Marking

The idler and idler sets may also be marked with the Standard Mark.

8.2.1 The use of the Standard Mark is governed by the provisions of Bureau of Indian

Standards Act, 1986 and the rules and regulations made there under. The details of conditions

under which a licence for the use of Standard Mark may be granted to manufacturers or

producers may be obtained from the Bureau of Indian Standards.


14

ANNEX A

(Clause 2)

LIST OF REFERRED INDIAN STANDARDS

IS No. Title

IS 4240:1984 Glossary of conveyor terms and definitions

IS 11592:2000 Selection and Design of Belt Conveyors - Code of Practice

IS 9295:1983 Specification for steel tubes for idlers for troughed belt conveyors'

ANNEX

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(Please use A4 size sheet of paper only and type within fields indicated. Comments

on each clauses/sub-clauses/table/fig. etc be started on a fresh box. Information in

Column 4 should include reasons for the comments and suggestions for modified

wording of the clauses when the existing text is found not acceptable. Adherence to

this format facilitates Secretariat’s work)

Doc. No.: ______________ TITLE: ________________________________________

LAST DATE OF COMMENTS: ________________

NAME OF THE COMMENTATOR/ORGANIZATION: _________________________

Sl.

No.

Clause/Subclause/

para/table/fig.

No. commented

Commentator/

Organization/

Abbreviation

Type of Comments

(General/Editorial/

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Justification

Proposed

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