AA SPECIFICATION RECONDITIONING OF CONVEYOR PULLEYS

371002 ISSUE 0 COPYRIGHT

CONTENTS 1 2 3 4 4.1 4.2 4.3 4.4 4.5 4.6 5 6 6.1 6.2 6.3 7 SCOPE

PAGE 2 2 2 2 2 2 3 3 3 4 4 4 4 4 4 4 5 5

TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER DEFINITIONS REQUIREMENTS NEW COMPONENTS CLEANING AND STRIPPING ASSESSMENT SHAFTS SHELLS CORROSION PROTECTION QUALITY ASSURANCE PROVISIONS TEST AND INSPECTION METHODS PULLEY SHAFTS END DISCS WELDING MARKING AND PACKING

APPENDIX A: RELATED DOCUMENTS APPENDIX B: RECORD OF AMENDMENTS

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AA SPECIFICATION RECONDITIONING OF CONVEYOR PULLEYS

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SCOPE
This specification details the requirements for the repair and reconditioning of belt conveyor pulleys suitable for both textile reinforced and steel cord conveyor belting and shall be read in conjunction with AA Specification 371001. The supply of bearings is excluded from this Specification.

TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER

The following requirements shall be specified in every tender, order or contract Title, reference number, issue and date of this specification Title, issue and date of applicable drawings Diameter, face length and hub bore diameter If the pulley is crowned Type of lagging Type of repair required e.g. full repair as per strip & quote or repair & return.

DEFINITIONS
For the purpose of this specification the following definitions shall apply: BS SABS : : British Standard South African Bureau of Standards

The following terms are defined in the Conditions of Contract: Anglo American, Approved, Engineer, Company, Contractor

4 4.1

REQUIREMENTS NEW COMPONENTS

New components shall comply with the requirements of AA Specification 371001. All replacement components shall be new unless otherwise approved. All repaired Pulleys shall carry a 6 month warranty from date of installation.

4.2

CLEANING AND STRIPPING

Pulleys shall be cleaned by means of a high-pressure water jet to remove loose dirt and rust prior to stripping. Items shall be suitably marked during the stripping process. Pulley lagging shall be completely removed by an approved method. All external shell surfaces shall be abrasive blast cleaned to SA 21/2 in accordance with AA Specification 164050. All paint, scale, rust and foreign matter shall be removed to facilitate inspection.

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Anglo Technical 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.

AA SPECIFICATION RECONDITIONING OF CONVEYOR PULLEYS

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4.3

ASSESSMENT
A detailed assessment report shall be submitted with the quotation. Shafts shall be checked between lathe centres for straightness. Run out of more than 0.5mm shall be cause for rejection. Shafts shall be dimensionally inspected and the results compared to the original drawing and or the bearing manufacturers tolerances. Dimensions outside the original tolerance shall be cause for rejection. Shell and End Discs shall be visually and dimensionally inspected and the results compared to the original drawing. Mechanical damage that would prevent the Pulley from fulfilling its intended duty shall be cause for rejection Shell thickness wear in excess of the following shall be cause for rejection TABLE 1
Original Shell Thickness 18mm 22mm Minimum New Shell Thickness 16mm 20mm Minimum Repair Shell Thickness 14mm 17mm

All other dimensions shall comply with the approved drawing and the requirements of AA Specification 371001.Unless otherwise approved by the Engineer. Locking elements shall be visually inspected for wear, damage and corrosion pitting. Components unsuitable for transmitting the required maximum torque that can be developed by the pulley shaft irrespective of whether the pulley is driving or idling shall be cause for rejection.

4.4

SHAFTS
New shafts shall be manufactured from steel which complies with the requirements of BS EN 10095:1999, Grade 070M20 (EN3A). Shafts shall be machined in accordance with the approved drawing. The use of steel conforming to BS EN 10095 080M40 (EN8) or 070M55 (EN9) is prohibited. All bearing, seal, locking element, coupling and shaft attachment diameters shall be machined to a surface finish of 1.6. Undercuts, reliefs and grooves are not permitted.

4.5

SHELLS
New shells shall be manufactured from steel, which complies with the requirements of SANS 1431 Grade 300 WA. All dimensions shall comply with the approved drawing and AA Specification 371001.

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AA SPECIFICATION RECONDITIONING OF CONVEYOR PULLEYS

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Longitudinal welds shall be in accordance with BS EN 1011-1/2. Circumferential welds are not permitted.

4.6

CORROSION PROTECTION
Corrosion protection shall comply with the requirements of AA Specification 164050. Prior to painting, all rust, mill scale, grease, oil and other foreign matter shall be removed. The shell, when not lagged, the hubs and end disks and diaphragms shall be primed with one coat of single pack wash primer of not less than 20m thickness and a single coat of chlorinated rubber, resin based paint of not less than 30m thickness.

QUALITY ASSURANCE PROVISIONS

The requirements of AA STD 100 shall apply.

6 6.1

TEST AND INSPECTION METHODS PULLEY SHAFTS

Pulley shafts shall be subject to Ultrasonic and Magnetic Particle testing in accordance with AA Specification 999000.

6.2

END DISCS
End discs shall be subject to Ultrasonic and Magnetic Particle testing in accordance with AA Specification 999000.

6.3

WELDING
Welding shall be subject to Ultrasonic and Magnetic Particle testing before and after stress relief in accordance with BS EN 1011-1/2.

MARKING AND PACKING

The following data shall be clearly marked in a non-stressed area of both end discs: Contractors name or logo Companies unique number Month and year of repair

Pulleys shall be suitably protected to provide a minimum of six months protection against corrosion or damage during storage. Pulleys shall be protected against inadvertent damage during handling and transportation. Copies of manufacturing test and inspection data shall accompany the delivery.

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Anglo Technical 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.

AA SPECIFICATION RECONDITIONING OF CONVEYOR PULLEYS

371002 ISSUE 0 COPYRIGHT

APPENDIX A: RELATED DOCUMENTS

AA Spec 371002: Reconditioning of Conveyor Pulleys

The latest issue of the following documents shall form part of this specification: AA Spec 164050 AA Spec 371001 AA Spec 999000 AA STD 100 BS EN 10095 BS EN 1011-1/2 BS EN 10293:2005 SANS 1431 : : : : : : : : Corrosion Protection of Steelwork with Coatings Conveyor Pulleys and Shafts Non-destructive Testing Quality requirements for Suppliers of Critical and Major Equipment Heat Resisting Steel and Nickel Alloys Recommendations for Welding of Metallic Materials Steel Castings for General Engineering Uses Weldable Structural Steel

APPENDIX B: RECORD OF AMENDMENTS Issue 0 : New document based on AAC Specification 371002 Rev. 0 (Paul Nel, January 2010)

AA_SPEC_371002.doc

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Anglo Technical 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.