Standard Technology

Title: Belt Conveyor Mechanical Unique Identifier: 240-55864503

Components Standard

Alternative Reference Number: GGSS 0406

Area of Applicability: Engineering

Documentation Type: Standard

Revision: 1

Total Pages: 20

Next Review Date: November 2015

Disclosure Classification: CONTROLLED

DISCLOSURE

Compiled by Approved by Authorised by

.. .. ..

M.Masina A. Wiid M Bagus

Senior Engineer Corporate specialist Corporate specialist

Date: Date: Date:

Supported by TDAC

..

D. Odendaal
TDAC Chairperson

Date:
 Belt Conveyor Mechanical Components Standard Unique Identifier: 240-55864503
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CONTENTS
Page
1. INTRODUCTION ...................................................................................................................................................... 4
2. SUPPORTING CLAUSES ........................................................................................................................................ 4
2.1 SCOPE .............................................................................................................................................................. 4
2.1.1 Purpose ..................................................................................................................................................... 4
2.1.2 Applicability................................................................................................................................................ 4
2.2 NORMATIVE/INFORMATIVE REFERENCES .................................................................................................. 4
2.2.1 Normative .................................................................................................................................................. 4
2.2.2 Informative ................................................................................................................................................. 6
2.3 DEFINITIONS .................................................................................................................................................... 6
2.3.1 Classification ............................................................................................................................................. 6
2.4 ABBREVIATIONS .............................................................................................................................................. 6
2.5 ROLES AND RESPONSIBILITIES .................................................................................................................... 6
2.6 PROCESS FOR MONITORING ........................................................................................................................ 6
2.7 RELATED/SUPPORTING DOCUMENTS ......................................................................................................... 7
3. BELT CONVEYOR MECHANICAL COMPONENTS .............................................................................................. 7
3.1 REQUIREMENTS .............................................................................................................................................. 7
3.1.1 General ...................................................................................................................................................... 7
3.1.1.1 Standard Conflict ............................................................................................................................... 7
3.1.1.2 Units and Dimensions ....................................................................................................................... 7
3.1.1.3 Standardization ................................................................................................................................. 7
3.1.1.4 Deviations .......................................................................................................................................... 7
3.1.1.5 Materials ............................................................................................................................................ 7
3.1.2 Design ....................................................................................................................................................... 8
3.1.2.1 General.............................................................................................................................................. 8
3.1.2.2 Allowable Stresses ............................................................................................................................ 8
3.1.2.3 Service Factors ................................................................................................................................. 8
3.1.2.3.1 General ..................................................................................................................................... 8
3.1.2.3.2 Gearboxes ................................................................................................................................. 8
3.1.2.3.3 Couplings, Shafts, V-Belt and Chain Drives ............................................................................. 8
3.1.3 Castings ..................................................................................................................................................... 8
3.1.4 Forgings ..................................................................................................................................................... 9
3.1.5 Gearboxes ................................................................................................................................................. 9
3.1.5.1 General.............................................................................................................................................. 9
3.1.5.2 Housings ......................................................................................................................................... 10
3.1.5.3 Shafts and Gears ............................................................................................................................ 10
3.1.5.4 Baseplates and Lantern Housings .................................................................................................. 11
3.1.6 V-Belts and V-Belt Pulleys ...................................................................................................................... 12
3.1.7 Roller Chain Transmission ...................................................................................................................... 12
3.1.8 Plummerblocks and Bearings.................................................................................................................. 12
3.1.9 High Speed Couplings ............................................................................................................................. 13
3.1.10 Low Speed Couplings ........................................................................................................................... 14
3.1.11 Brakes ................................................................................................................................................... 14
3.1.12 Lubrication ............................................................................................................................................. 14
3.1.13 Cranes, Hoists and Crawl Beams ......................................................................................................... 15
3.1.14 Wire Rope, Chains and Fittings............................................................................................................. 15
3.1.15 Hydraulic Systems ................................................................................................................................. 16
3.1.16 Access Platforms and Walkways .......................................................................................................... 17
3.1.17 Guards and Safety Requirements ......................................................................................................... 18
3.1.18 Fasteners............................................................................................................................................... 19
4. AUTHORISATION .................................................................................................................................................. 20
5. REVISIONS ............................................................................................................................................................ 20

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6. DEVELOPMENT TEAM ......................................................................................................................................... 20

7. ACKNOWLEDGEMENTS ...................................................................................................................................... 20

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1. INTRODUCTION

This standard defines the requirements for the mechanical part of all machinery, equipment and plant to
be purchased by Eskom for the Power Station as defined in the Scope of Work.

2. SUPPORTING CLAUSES

2.1 SCOPE

None

2.1.1 Purpose

None

2.1.2 Applicability

This document shall apply throughout Eskom Holdings Limited Divisions.

2.2 NORMATIVE/INFORMATIVE REFERENCES

Parties using this document shall apply the most recent edition of the documents listed in the following
paragraphs.

2.2.1 Normative

[1] F.E.M. (Federation Europeene de la Manutention): Section 1 Second Edition, December 1970,
Appliance Group D.
[2] ISO 113-2:1979, Rolling bearing accessories Part 2: Plummer block housings. ISO 1328:1975,
Parallel involute gears - ISO system of accuracy.
[3] ISO 2372:1972, Mechanical vibrations of machines with operating speeds from 10 revs/s to 200
revs/s - Basis for specifying evaluation standards.
[4] ISO 5049-1:1980, Mobile Continuous Bulk Handling Equipment Part 1 : Rules for the design of
structures with amendments as described in this specification.
[5] BS 228:1984, Specification for short pitch transmission precision roller chains and chain wheels.
[6] BS 436-1:1967 (1987), Spur and helical gears Part 1: Basic rack form, pitches and accuracy.
[7] BS 436-2:1970 (1984), Spur and helical gears Part 2: Basic rack form, modules and accuracy.
[8] BS 436-3:1986, Spur and helical gears Part 3: Method for calculation of contact and root
stresses.
[9] BS 449-2:1969, Specification for the use of structural steel in building Part 2: Metric units.
[10] BS 545:1982 (1987), Specification for bevel gears.
[11] BS 970-1:1991, Specification for wrought steels for mechanical and allied engineering purposes
Part 1: General inspection and testing procedures and specific requirements for carbon, carbon
manganese, alloy and stainless steels.
[12] BS 1452:1990, Specification for flake graphite cast iron.

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[13] BS 1486-1:1959 (1982), Lubricating nipples Part 1 : Lubricating nipples and adaptors for use on
machinery and vehicles.
[14] BS 1916-1:1953 (1985), Limits and fits for engineering Part 1: Limits and tolerances.
[15] BS 1916-2:1953 (1985), Limits and fits for engineering Part 2: Guide to the selection of fits in BS
1916-1.
[16] BS 2853:1957, The design and testing of steel overhead runway beams.
[17] BS 2890:1989, Specification for troughed belt conveyors.
[18] BS 3100:1991, Specification for steel castings for general engineering purposes.
[19] BS 3790:1981, Specification for endless wedge belt drives and endless V-belt drives.
[20] BS 4235-1:1972 (1986), Specification for metric keys and keyways Parallel and taper keys.
[21] BS 4235-2:1977 (1985), Specification for metric keys and keyways Woodruff keys and keyways.
[22] BS 4360:1990, Specification for weldable structural steel.
Lubrication
[23] BS 1399-1:1970, Specification for rotary shaft lip seals Part 1: Dimensions of shafts and
housings.
[24] SABS 053:1972, Standard viscosity classification of industrial lubricating oils.
[25] SABS 344:1974, Calcium-base lubricating grease.
[26] SABS 351:1974, Sodium-base lubricating grease.
[27] SABS 406:1974, Lithium-base lubricating grease.
[28] SABS 1014:1974, Multi-purpose lubricating grease.
Cranes, hoists and crawl beams
[29] BS 3243:1990, Specification for hand operated chain blocks.
[30] NWS 1408, Specification for Wire Rope Electric Hoist Unit.
[31] NWS 1518, Specification for hand operated travelling cranes.
Wire rope, chains and fittings
[32] BS 302-2:1987, Stranded steel wire ropes Part 2: Specification for ropes for general purposes.
[33] BS 463-2:1970, Specification for sockets for wire ropes.
[34] BS 4278:1984, Specification for eyebolts for lifting purposes.
[35] SABS 189:1993, Short-link steel chain (medium tolerance) for lifting purposes.
[36] SABS 811:1974, Rope thimbles.
[37] SABS 812:1973, Mild steel shackles.
[38] SABS 813:1973, Clamps for wire ropes.
Hydraulic systems
[39] BS 1710:1984 (1991), Specification for identification of pipeline and services.
[40] BS 3600:1976 (1988), Specification for dimensions and masses per unit length of welded
seamless steel pipes and tubes for pressure purposes.

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[41] BS 3832:1991, Specification for wire reinforced rubber hoses and hose assemblies for hydraulic
installations.
[42] BS 4368-1:1972 (1984), Compression couplings for tubes Part 1: Specification for heavy series
couplings (metric).
[43] BS 4586:1984, Specification for spiral wire reinforced rubber covered hydraulic hoses and hose
assemblies.
[44] NCB 174, Hydraulic hose fittings.
[45] NWS 1059, The identification of contents of pipelines and vessels. Fasteners
[46] SABS 094:1982 (1992), The use of high-strength friction grip bolts. SABS 646:1962, Precision-
bolts, screws and nuts.
[47] SABS 135:1991, ISO metric bolts, screws and nuts (hexagon and square) (coarse thread free fit
series).
[48] SABS 136:1991, ISO metric precision hexagon-head bolts and screws and hexagon nuts (coarse
thread medium fit series).
[49] SABS 1143:1977, Mushroom-head and countersunk-head bolts and nuts.
Where an equivalent specification is proposed this shall be subject to approval in writing by the
Engineer.

2.2.2 Informative

None

2.3 DEFINITIONS
Definition Description
Approved Approved by Eskom

2.3.1 Classification

Controlled Disclosure: Controlled Disclosure to External Parties (either enforced by law, or

discretionary).

2.4 ABBREVIATIONS

Abbreviation Description
AGMA American Gear Manufacturers' Association.
NCB National Coal Board in the U.K.

2.5 ROLES AND RESPONSIBILITIES

None

2.6 PROCESS FOR MONITORING

None

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2.7 RELATED/SUPPORTING DOCUMENTS

None

3. BELT CONVEYOR MECHANICAL COMPONENTS

3.1 REQUIREMENTS

3.1.1 General

3.1.1.1 Standard Conflict

In the event of a conflict between specifications, the more stringent shall apply, unless otherwise stated
in this document.
It is the responsibility of all Contractors to state the specifications to which their equipment is designed
and manufactured.

3.1.1.2 Units and Dimensions

The SI system of units (Systeme International d'unites) shall be used throughout.

All dimensions and units appearing on drawings, calculation sheets and other documentation shall be
consistent with the SI system as interpreted within the Republic of South Africa.

3.1.1.3 Standardization

Interchangeability of components shall be maximized. Tolerances and limits and fits shall be selected
such that no modifications shall be necessary when replacement of components are subsequently
purchased from the manufacturer, or his proprietary item supplier(s).

3.1.1.4 Deviations

Any deviation from this specification shall be clearly stated in writing.

Absence of such statements shall be interpreted to mean that the offer is in compliance with this
specification.

3.1.1.5 Materials

The contractor shall furnish certified test reports and materials when required.
The chemical composition, tensile strength, elastic limit and elongation, etc. of the various materials
employed, shall under no circumstances be inferior in quality to the minimum requirements of the
relevant standard.
All components and materials of construction shall be new.
No castings, forgings or other material in a condition known to be faulty will be accepted even under
guarantee of replacement in case of failure.
The necessary dimensional allowances shall be made on forgings and castings to ensure the correct
finishing and final sizes of the forged/cast component after machining.

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3.1.2 Design

3.1.2.1 General

All equipment shall be designed in accordance with the following general design practice:
Inspection, maintenance, repairs and cleaning shall be executable with a maximum of ease and full
accessibility.
Vibrations generated by the equipment shall be minimized and shall not cause significant
deflections, the loosening of connections, oil leaks, etc.
Noise levels shall be kept to a minimum such that operators may perform their duties in reasonable
comfort. Resonating and reverberating effects shall be eliminated.

3.1.2.2 Allowable Stresses

The design shall be undertaken in accordance with the previously specified standards.
In addition full consideration shall be given to the duty of equipment and its associated components
when determining the allowable stress for operational purposes.
All aspects of static and dynamic effects shall be carefully considered to ensure that excessive elastic
deflection, plastic failure, fatigue failure, fretting etc. does not occur.

3.1.2.3 Service Factors

3.1.2.3.1 General

These shall be selected in accordance with relevant standards and specifications with due regard to
proprietary equipment manufacturers' recommendations.
For continuous duty and heavy shock loading the service factors shall be individually considered and
specified.
For medium duty and light shock loading the following shall apply unless otherwise stated:

3.1.2.3.2 Gearboxes

A minimum service factor of 1,25 shall be applied i.r.o. the installed motor power. Thermal ratings shall
be adequate for a continuous full load duty based on the maximum ambient temperature specified, shall
be a minimum equal to 1,1 times the installed power and shall be selected to ensure that the lubricating
oil will not exceed 110 C. All other reducer components shall have a nominal statistical life of not less
than that of the bearings.

3.1.2.3.3 Couplings, Shafts, V-Belt and Chain Drives

The applicable service factor shall be 1,25 on installed motor power.

3.1.3 Castings

All castings of every kind shall be thoroughly cleaned of fins and sand before painting.
No painting or filling-in of castings will be allowed until such castings have been inspected. No
rectification of castings shall be undertaken without the written consent of the Engineer.

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All iron castings shall be of the best, strong, close-grained quality and shall conform to the requirements
of BS 1452 - Grey iron castings, unless otherwise specified. Grades 10 or 12 shall be provided according
to the duty of the castings. Both tensile and transverse tests shall be made in accordance with clause 9
and clause 10 of BS 1452.
All steel castings shall comply with the appropriate specification appearing in BS 3100 unless otherwise
specified.
If iron or steel castings are offered to any specification other than those given above, the Contractor shall
supply full details of such other specifications.

3.1.4 Forgings

All forgings shall be of suitable quality steel and, after forging operations had been completed, shall be
subjected to the necessary heat treatment to yield the required physical properties and to relieve all
stresses before any machining.

3.1.5 Gearboxes

3.1.5.1 General

The input speed of gearboxes shall generally be that of a 4-pole motor. Due regard shall, however, be
taken of the actual output speed at FLT, and the slip of fluid couplings where fitted. Output speeds shall
relate to drive pulley selection including, the effect of pulley lagging. As such, the required ratios shall lie
within 5 % of the actual gearbox ratios.
NOTE: Do not adopt catalogue ratios as these may be nominal values.
Gearbox inefficiency shall be limited to 1,5 % per reduction stage for helical types (worm type boxes may
only be used with written permission of the Engineer). All gearboxes shall be in accordance with the
latest AGMA standards. The nominal operation life of all gearboxes shall be greater than 100 000 hours
under full load. All other reducer components shall have a nominal statistical life of not less than that of
the bearings.
In general, all reducers shall be of the parallel shaft type incorporating helical gears. All first reduction
gearing shall be of the helical type, except where right-angle drives are used, in order to reduce the
noise level.
The use of specialized or non-standard type gearboxes should however be kept to a minimum (for
example epicyclic) and will only be allowed with Eskom's approval in writing.
Gearboxes shall be symmetrical so that handing, shaft rotation and reducer position, relative to the
equipment, may be easily altered. All shaft mounted gearboxes shall be installed such that the output
torque produces a moment such that the overhung load on the drive shaft extension is minimized. (Shaft
mounted gearboxes will only be allowed with Eskom's approval in writing).
All drive units shall be supplied with all drive components correctly machined and assembled on the
base plate. Use shall be made of suitable shims, packs and dowels to ensure interchangeability.
Each fully assembled drive unit shall be subject to a 24 hour no-load shop test run. During this test,
vibration levels, temperature rise, noise levels, etc. shall be recorded at hourly intervals and submitted to
the Engineer for approval.
Generally, shaft mounted gearboxes shall be bevel/helical type for use with a Rigid Bikon or equivalent
coupling element. Bikon elements, or the equivalent, shall be used on both coupling halves. The size of
the coupling shall be selected with a factor of safety or not less than 2; based on the maximum bending
load and torque.

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Shaft mounting via rigid steel couplings is only permitted if the coupling halves are self-aligning and easy
to remove. The bearings for the bevel stage of the gearbox must be suitable for the loading involved.
Direction of rotation of both input and output shafts shall be clearly indicated by suitable markings.

3.1.5.2 Housings

All housings shall be made of:

high grade close-grained cast iron to BS 1452 Grade 17 or better with tensile strength greater than
200 N/mm2; or
fabricated steel to BS 4360 or the equivalent DIN specification, with a minimum tensile strength of
250 N/mm2 and shall be stress relieved before final machining.
All gearboxes shall be:
rigidly constructed;
totally enclosed, dust-proof, hose-proof and oil tight;
equipped with inspection covers, drain and filler plugs, oil seals, gaskets and breather holes; and
be equipped with lifting lugs.
Vent filters shall be of the renewable element type. Sight glass level indicators, clearly marked with
running and stationary oil levels shall be used and the gearboxes shall be fitted with drain cocks. The
complete drive units shall be mounted such that there is adequate clearance below the drain wells to
facilitate maintenance, e.g. being at least 250 mm above the nearest obstruction and fully accessible.
Drain plugs shall have magnetic inserts.
Housings shall be thoroughly cleaned and shot blasted in the case of castings and shall be subjected to
paraffin tests for oil-tightness prior to being painted on the inside.
For internal painting, an oil resistant, ivory coloured paint shall be used.
All housings shall be designed to withstand the combined effects of the radial, axial and overhung loads
applicable to drives having the maximum permissible misalignment.
Special attention shall be paid to the strength of the housing and the inboard bearing of the input shaft of
right-angled drive reducers.

3.1.5.3 Shafts and Gears

All shafts shall be made of high quality heat treated alloys to BS 970 or equivalent relevant international
standards. They shall be tempered and ground to reduce notch sensitivity to a minimum.
The maximum allowable stress in a shaft during operation shall not exceed 1,5 times the calculated
fatigue limit for the material based on the maximum applied torque and loading criteria. Clamping
assemblies shall have a minimum factor of safety against slip of 2:1. Failure through corrosion fatigue
shall be minimised. Tolerances on shafts shall be in accordance with the requirements Part 1 and Part 2
of BS 1916.
Shafts shall withstand combined torsion and bending without undue deflection.
Shaft diameter reductions for bearings shall be limited to 10 % of the normal shaft diameter and shall
have fillet radii of at least 3 times the step height. Sharp or undercut corners shall be avoided.
Shafts shall be concentric and the finish shall be smooth and free from any indentations. The applicable
notch effects of keyways and shoulders shall be allowed for.

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If parallel or taper keys, either with or without gib heads, are used for applications transmitting heavy
shock loads, EN 6A, EN 8 or EN 9 steel shall be used : mild steel or EN 3 steel is unacceptable. Friction-
based, releasable clamping assemblies of approved manufacture or equivalent shall be used where
possible for fastening items, such as pulleys, chain wheels, etc. to shafts.
The keys and keyways shall comply with the requirements of BS 4235 Parts 1 and 2. All keys shall be
positively located or secured by keepers where required.
Shafts shall be mounted in anti-friction bearings that are located in precision machined bearing housings.
The gearboxes shall be fitted with multiple seals consisting of a standard inner oil seal combined with an
outer seal of the grease charged labyrinth type.
All gearboxes with right-angle shafts shall have a bevel/helical gear set with spiral teeth on the high
speed side.
Pinions and gear wheels shall be made from alloy steel forgings, followed by a surface heat treatment of
root and flank of the tooth. If wheels are carburised, the tooth flanks and profile shall be ground and the
gear pair lapped together. Case-hardening shall be by means of a carburizing process. Nitriding or flame
hardening of gears is not acceptable.
The surface hardness of the pinion and gear before cutting shall not be less than 210 BHN (Brinell
Hardness) and 180 BHN respectively. The surface hardness of a case carburised steel shall not be less
than 55 RC (Rockwell Hardness) and induction hardened surfaces shall not be less than 50 RC.
Carburised wheels shall be stress relieved before grinding.
Gears shall be made of heat treated alloy steel to BS 970 : Part 1.
The design and machining of gear teeth shall be in accordance with the following specifications in the
priority shown:
AGMA requirements, or
BS 436 and BS 545 or
DIN specifications.

3.1.5.4 Baseplates and Lantern Housings

All baseplates and lantern housings shall be fabricated from steel which is in accordance with BS 4360
Grade 43A minimum.
Baseplates shall be so designed that handing, shaft rotation and baseplate position is interchangeable
with similar units installed on the equipment. The bed plate shall be stress relieved after fabrication and
prior to machining.
The combination bed plate shall be sufficiently rigid to withstand the static and dynamic loading of the
drive without reliance upon grouting.
Both bearing surfaces and support pads shall be machined true and parallel.
Where any relative movement between the reducer and the drive pulley can occur e.g. a flexible
cantilevered head frame, the bed plate shall be rigidly fixed to the drive frame.
The combination bed plate shall be fitted with suitable jacking bolts to facilitate alignment of the drive.
Jacking bolts shall be a minimum of M12. M16 shall be used where the distance between the lug and the
base plate exceeds 100 mm. The jacking bolt contact shall allow a minimum of 5 mm vertical shimming.
Use shall be made of suitable shims, packs and dowels to ensure easy component replacement and
interchangeability.

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The baseplate or lantern housing shall accommodate the following components:

a. the high speed components;
b. safety guards over high speed couplings and brakes;
c. oil splash-proof guards over fluid couplings; and
d. lifting lugs.

3.1.6 V-Belts and V-Belt Pulleys

V-belts and V-belt pulleys, other than those for automotive and variable speed drives, shall comply with
the provisions of BS 3790.
Poly-V drives are not acceptable.
All V-belt drives shall be designed to incorporate sizes of V-belts commonly used in the Republic of
South Africa.
For multi-belt applications, matched belts shall be supplied to avoid uneven load distribution.
All V-belt pulleys shall preferably be fitted with taper locked bushes, to facilitate fitting and replacement.
Jackshafts shall be used on heavy duty drives where belt tensions are high.
Driving motors shall be mounted on slide or pivoted bases allowing sufficient adjustment for correct belt
tensioning. Bases shall incorporate jack screws with lock nuts.

3.1.7 Roller Chain Transmission

Chain drives shall be in accordance with BS 228.

Sufficient take-up allowance on the motor shall be provided to take up two full chain links. Where take-up
allowance is not possible due to fixed wheel centres, an adjustable chain wheel idler shall be
incorporated.
All chain drives shall be adequately guarded and lubricated.

3.1.8 Plummerblocks and Bearings

Shafts shall be supported by rolling bearings or self-aligning ball bearings adequately sized to
accommodate static, dynamic radial and any anticipated end thrust loading. Generally, on designs where
the end thrust loading is zero, a nominal value will be included to allow for any misalignment on
installation.
Where taper roller bearings are used adequate provision shall be made for adjustment with maximum
ease. Adjustment facilities must be positively lockable.
The LIO bearing life will in all cases be checked to ensure a life of at least 50 000 hours at full load.
Care shall be exercised to ensure that the correct limits are selected for shafts and housings to suit a
particular bearing. Bearings shall be arranged for easy replacement without major dismantling.
All bearings shall be adequately sealed against the ingress of dust, grit and moisture and shall be
provided with suitable button - headed nipples in accordance with paragraph 1.20 of this specification.
Seals shall be designed for outdoor service in an environment containing fine abrasive dust and shall be
of the grease charged horizontal mechanical labyrinth type. Felt or fibre packings shall not be used as
dynamic seals.

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Only local standard stock sizes shall be used and special bearings shall be avoided. Housing
dimensions shall be in accordance with ISO 113-2.
Type SNH self-aligning ball bearing plummerblocks or approved equivalents shall be provided for shaft
sizes up to and including 80 mm. For shaft sizes above 80 mm and up to 140 mm, type SNH roller
bearing plummerblocks or approved equivalents shall be used.
For shaft sizes above 140 mm type SD roller bearing plummerblocks, or an approved equivalent shall be
used and supplied complete with hydraulic nut facilities for mounting and dismounting.
Bearing sets shall consist of one locating and one non-locating bearing.
Bearing housings shall be fitted with blanking plates where the shafts do not protrude.
Bearing sets shall be located in accordance with the requirements of the assembly.
All plummerblocks shall have low shear loadings and the resultant of all forces on the
plummerblocks/bearing shall act through the base and preferably be perpendicular to the sole plate. All
plummerblocks shall be supported along their full face width and face length. Whenever recesses cause
difficult access, split roller bearings shall be used.
Forces other than those acting at right angles to the base shall not exceed the plummerblocks/bearing
manufacturer's specified allowance.
Bolts used on plummerblocks shall be galvanized, and shall not be painted afterwards to ensure easy
dismantling.

3.1.9 High Speed Couplings

For drives up to 15 kW, rubber type couplings shall be used. For fixed speed drive units of 10 kW and
above, fluid couplings shall be used.
The fluid couplings shall be of a type that ensures a smooth and controlled start-up when required.
During starting, the controlled slip shall limit the torque to a maximum of 140 % of the calculated full load
torque. During normal full load running the slip shall not exceed 4 %.
All fluid couplings shall be fitted with a correctly selected thermally operated pin type fusible plug and
micro switch (to trip the motor on operation of the pin) together with at least one normal fusible plug, of
higher activation temperature than the pin type.
The couplings shall be capable of at least six start-ups of equal duration under full load in 60 minutes or
as many start-ups as the motor is capable of in 60 minutes, whichever is the greater. To this end, the
couplings shall be sized on installed motor power but taking cognisance of absorbed power.
Vibration shall be limited in accordance with ISO 2372 Machine Group IV whilst the r.m.s. velocity
tolerance of the range shall not to exceed 7,1 mm/s.
In the stall position (100 % slip), the fluid coupling output torque shall be limited to twice the full load
torque with the oil fill level set to the 140 % full load torque required on starting.
Tenderers may offer as an alternative, scoop control or programmable fluid couplings should it be
considered that a reduction in belt class and/or improved starting characteristics will result by limiting the
acceleration factor.
Conveyors employing multiple drum drives shall be supplied complete with a re-programmable
microprocessor to control full load torque and motor slip and provide both for load compensation (within
a range of 7 percent) and inspection mode selection to an operating value as defined in the project
specification. Couplings shall be rated for the installed motor power taking full cognisance of variations in
absorbed power and operating philosophy. Should this be proposed, full dynamic calculations must be
submitted to determine that the belt class selected complies with the requirements of the acceleration

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cycle. Conveyor simulated start-up characteristics shall be submitted to display torque and belt speed
against time.
The fluid couplings shall be mounted using at least one flexible coupling and be suitable for use with
braking devices even if the device is not fitted. The main load of the coupling shall be on the motor side.
Should a gear coupling be used for the flexible coupling, only a double gear coupling will be allowed. A
single gear coupling is unacceptable.
Name plates with coupling type, grade and quantity of oil required shall be fixed in a visible position on a
stationary part of the coupling guard. Maximum and minimum oil levels shall be marked.
Couplings shall be rated for the installed motor power and not the absorbed power.
Drip pans shall be provided under all fluid couplings. These shall be fixed in a position which will collect
oil discharged from the couplings. The drip-pan shall be of sufficient depth to contain the oil from the
couplings without overflow. Drip-pans shall be of robust construction with threaded leak-proof bottom
plugs. The shape of the pan and position of the outlet shall allow for easy tapping-off into a container.
Fluid couplings shall have a thermal pin/sonic pick-up prior to fusible plug giving way.
Fluid coupling covers shall withstand wash-downs by hose.

3.1.10 Low Speed Couplings

Where drive units are shaft mounted, preference will be given to rigid locking elements of the Stuwe type
or equivalent.
Drive units which are not shaft mounted shall be fitted with flexible couplings incorporating suitably
tempered alloy steel flexible grid members, i.e. FaIk "Steelflex" or equivalent. These shall be installed
within the manufacturers axial and radial tolerances, and consequently the couplings shall be machined
to allow measurement of such tolerances.
The teeth of the couplings shall be machined to class 7 in accordance with ISO 1328 or equivalent (for
example, A2 in accordance with BS 436). The couplings shall be aligned radially, angularly and axially to
within the manufacturer's tolerance.
In addition, the radial misalignment shall not exceed 0,001 times the coupling diameter.

3.1.11 Brakes

The sizing and ratings of the brakes, when required, shall be based on the deceleration time of the item
of plant, but also such that the items of equipment cannot rotate under all the conditions specified.
The brakes shall be either of the drum type or disc type with electro-hydraulic thrustors. Due to their time
delay on releasing, only instantaneously acting thrustors shall be used on drives that do not have fluid
couplings. Thrustors, once set, shall retain their speed of operation without a need for frequent resetting.

3.1.12 Lubrication

All bearings, except sealed-for-life types, shall have provision for efficient lubrication and where possible,
adjacent lubrication points should be grouped. When specified, centralised greasing systems shall be
employed and shall have the following characteristics:
be automatic in operation;
incorporate manual back-up; and
incorporate simple "proof of delivery of grease" on grease line terminal points.

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All lubricating points shall be conveniently accessible and approved extension pipes shall be provided for
all points behind guards and casings or in inaccessible positions. Lubrication nipples for grease
lubrication shall be standardized throughout the equipment and these shall be only of the button-headed
type in accordance with BS 1486 with type 21A, 8 mm ISO R7 pipe threads.
Enclosed oil bath type or some other acceptable automatic means shall be used for the lubrication of
chain drives. All oil baths shall be fitted with effective seals to prevent ingress of dust, as well as filler
points, drains and inspection facilities.
Where special lubricants are required for certain items of equipment, suitable labels shall be provided
indicating the type and quantity of lubricant required and these shall be fixed near the pertinent
lubricating points.
All drip-pans shall be of robust construction with threaded bottom plugs, and shall not allow leakage of
oil. The shape of the pan and position of outlet shall allow for easy tapping-off of the oil in the pan, into a
container.
The drip-pan shall have enough depth, to contain all the oil from reducers or couplings. In the case of
fluid couplings the guard shall be such that in the event of fusible plug operation, all the oil is directed
into the drip-tray.
A complete initial charge of lubricant for all equipment shall be supplied and lubrication carried out by the
Contractor before commissioning. Flushing oils shall be provided by the Contractor, and no equipment
shall be filled with oil unless it has been thoroughly flushed. The flushing and filling of equipment shall be
subject to witnessing by an Eskom Engineer.
A complete chart of lubricants recommended for the various items of equipment shall be submitted to
Eskom for approval and shall be incorporated in the operating and maintenance manuals. The quality,
grade and quantity of lubricant shall be clearly stamped on every piece of equipment requiring
lubrication.
In addition to any of the manufacturer's recommended products that have been approved by Eskom, the
following standards shall apply:
SABS 053, SABS 344; SABS 351, SABS 406, SABS 1014, and BS 1399.

3.1.13 Cranes, Hoists and Crawl Beams

All crawl and runway beams shall be designed in accordance with BS 2853 "The design and testing of
steel overhead runway beams".
The crane and wire rope electric hoist units shall be in accordance with: BS 3243, NWS 1408, and NWS
1518.
All other crawl beams shall be fitted with a trolley of the required capacity. The wire rope electric hoist
units shall have creep speed hoisting and a lowering speed of 10 % of normal speeds.
All crawl beams shall have the maximum allowable tonnage, that may be lifted, clearly painted on the
beam. This shall be repeated at 10 metre intervals where the beam length is greater than 10 m.
All lifting hooks shall be fitted with a spring loaded safety catch. The ends of all craw! And runway beams
shall be provided with adequate end stops.

3.1.14 Wire Rope, Chains and Fittings

Wire ropes, rope fittings, chains and chain fittings shall be in accordance with:
BS 302, BS 463-2, SABS 811, SABS 812, and SABS 813.
Eyebolts for lifting purposes shall comply with BS 4278.

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All ropes, whether fixed suspension or for general use shall comply with all relevant Acts and statutory
regulations.
Rope fittings shall be securely fitted to the ropes, preferably with terminal splicing standard spelter
fittings or approved swaged fittings. All rope slings shall be tested to twice the safe working load. Spelter
fittings shall not be used for high temperature applications. Where rope clips are specified, no less than
three rope clips shall be fitted to make a connection.
Conveyor take-up ropes shall be of the general construction steel wire rope type and the diameter shall
be calculated using a factor of safety that is the greater of
6; or

Where T = tension in the rope in kN.

Sheave diameters, equal to 22 times the rope diameter, shall be used.
Rope slings for general use shall be fitted with a metal tab indicating the safe working load.
Chains shall be Grade 4 in accordance with SABS 189 and shall comply with all relevant Acts and
statutory regulations and shall be stamped indicating safe working load.
Sockets, thimbles, rigging screws, stretching screws, eyebolts, etc. shall have a safe working load of not
less than the attached rope or chain.
Wire rope and fittings that form a stationary part of a machine and fixed guys shall be galvanized.

3.1.15 Hydraulic Systems

Contractors shall describe the extent of the use of hydraulics, and include basic hydraulic flow diagrams
with their offers. Hydraulic system pressures shall be kept below 13,7 MPa and be fitted with trip control
pressure gauges. The use of flexible lines shall be kept to a minimum and shall conform to the
requirements of BS 3832 type B2 or BS 4586.
Adequate safety provisions shall be made in the event of component failure. Components which carry a
sustained load shall be of zero leak design. Cylinders shall be designed to hold or release under control,
all loads which might occur in either direction. Hydraulic systems for hoisting or luffing shall be equipped
with lock valves.
Motor and pump units shall be mounted on a common bedplate, in turn mounted on anti-vibration
mounts and have drainable drip trays. Each power pack shall be fitted with a standby pump and motor.
The hydraulic reservoirs, electric motors and pumps forming the power packs shall be housed in a
separate, ventilated room which shall be pressurised with a combined fan and self-cleaning filter. The
pressure shall not be less than 60 Pa and the air quantity shall be equivalent to ten changes per hour or
more. Oil reservoirs shall be protected from the effects of moisture condensation and corrosion within the
tank. Fluid level switches, over-temperature switches, and a means for completely draining the reservoir
and the system shall be provided. Reservoir breathers shall either be closed circuit or shall be equipped
with replaceable type filters of adequate capacity. Means of air bleeding of the system shall be provided
where necessary. Bleeding points shall be readily accessible.
Oil filters shall be of the "tell-tale" type, accessible and readily replaceable. Oil shall be filtered in
accordance with the component manufacturer's requirements and all make-up oil shall be filtered into the
reservoir.
Oil temperature measured at the hottest area in the oil reservoir shall not exceed 50 C above ambient
temperature. The use of oil coolers is not be permitted, and the reservoirs must therefore be adequately
sized.

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The oil type, quantity and viscosity shall be clearly and permanently marked on a plate and secured to
the reservoir.
Wherever possible pipe connections shall be welded. The use of breakable fittings shall be kept to a
minimum. All seals shall be compatible with the hydraulic fluid specified. Flexible hose assemblies shall
have swaged end fittings with female running-nuts at each end and shall be in accordance with the
National Coal Board specification number 174 and shall be installed in accordance with the
Manufacturer's recommendation giving particular attention to the following:
movement shall be in one plane and torsional stresses avoided;
rubbing against other hoses, machinery or structures shall be avoided;
greater than minimum recommended radii shall be used;
support in thrust and compression shall be provided; whilst
flexing distances shall be taken care of.
Pipework shall be as specified by the Contractor and approved by the Engineer. Pipework shall be
adequately supported and securely fixed immediately before and after a bend or off-set.
"Hemsheidt" staplelock fittings or equivalent may also be offered. Pipework shall conform to the following
standards:
BS 1710, BS 3600, BS 4368 and NWS 1059. Preference shall be given to cold drawn seamless tubing.
All steel pipework shall be adequately internally pickled, passivated, flushed and maintained hydraulically
clean thereafter. Preference will be given to pickling using a hydrofluoric acid process.
Pipe supports shall incorporate suitable vibration damping material and the support assembly shall not
damage the pipe.
Accumulators shall:
be of adequate volume for the required duty;
eliminate hydraulic shock (if installed to do so) and if of the rubber bladder type, shall not burst
internally or externally;
be capable of being isolated from the hydraulic system and in the isolated condition be able to drain
the fluid in the accumulator back to the reservoir; and
be automatically vented on system shutdown except where power conservation or standby supply is
required.
Ready access to filling points and for component maintenance and replacement shall be provided.

3.1.16 Access Platforms and Walkways

Suitable walkways, ladders and platforms, all fitted with handrails, and designed in accordance with BSS
449 shall be provided to give safe and easy access for maintenance and operating purposes to all parts
of the equipment which are not easily accessible from ground level. The design shall provide for
maximum safety of personnel.
All platforms, grating, etc., fitted directly above equipment shall be removable to allow access to the
equipment. The grating panels shall be clipped in position.
Handrails and intermediate rails shall be fitted to all sloping gangways and gangways from which a
person may fall 1,8 m or more. Handrails and stairs shall be built in accordance with drawing number
0.00/2901 Rev 4.

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NOTE Refer to GGSS 0407 Specification for structural steelwork and welding.
Walkways shall be adequately supported to take loads of 2,5 kN/m2 unless otherwise specified on
drawings. The walkway width between the conveyors shall equal the width of the spacing between the
conveyors as shown on the drawings. The minimum walkway width is 750 mm. No structure shall restrict
access up to a height of 2300 mm above the walkway.

3.1.17 Guards and Safety Requirements

The Contractor shall make all the necessary arrangements to guard or make safe all openings in floors,
e.g. hoistwells, conveyor openings, bin or shaft openings, etc. and where necessary, shall provide
protection in the form of handrailing or covers. The method of fixing the necessary guards and
handrailing shall be subject to Eskom's approval.
Adequate safety measures shall be provided throughout the Plant to meet the requirements of the
Occupational Health and Safety Act or such other act as may apply to the plant and these shall be
supplemented by warning notices fixed in positions as required by the Inspector of Machinery. The
Contractor shall also be required to ensure that the noise levels of all items of plant shall be limited to a
level of 85dB A at a distance of 1 m from the particular item.
Guards shall be provided in accordance with the requirements of BS 2890 and this specification at the
following positions:
all drive, snub, bend and take-up pulleys, excluding conveyor idler rolls unless otherwise specified;
conveyor idler rolls where the upward movement of the belt is restricted (e.g. loading points, skirt
plates); and
rotating machinery such as trippers, shafts and couplings, driving chains and chain wheels, gears,
driving belts and pulleys.
All rotating shaft ends shall be guarded.
Square or angle pinch guards shall be provided at all nip points in accordance with BS 2890 regardless
of the installation of panel guards. These pinch guards shall be rigidly bolted to the conveyor structure.
All guards shall be of robust construction using heavy duty mesh, "Type FE 7801 Expamet" or similar
and be bolted in position but shall, for the purpose of maintenance, be easy to remove and replace
(while the plant is not in operation). Without having to dismantle any other parts, guards for couplings,
pulleys, moving machinery, etc., shall be capable of supporting a point loading of 100 kg.
Where the clearance between the floor or ground level and a conveyor or other potentially dangerous
piece of machinery is greater than 800 mm but less than 2 300 mm, access shall be prevented by
suitable guard rails. When access is permitted beneath a conveyor, guards shall be provided under the
return belt and return idlers, and on both sides.
Guards at floor level shall be ended off 225 mm above floor level to permit cleaning.
Kick plates of 6 mm minimum thickness, protruding at least 100 mm above the flooring or walkway, shall
be provided on all elevated steel floors and walkways.
Gravity take-ups shall be enclosed with easily removable panels for maintenance and ended off at 225
mm from the ground. Where guards are provided in an area requiring routine maintenance, the
maintenance shall be performed without disturbing the guards.
Should access to a bearing be restricted, lubrication of the bearing shall be arranged from a remote
grease point.
All guard panels shall be fitted with handles to facilitate handling.

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Horizontal conveyor take-up carriages, moving on rails, shall be enclosed for the entire rail length with
removable guard panels except where the height above floor level exceeds 2 300 mm.
Fluid coupling guards shall be manufactured from heavy duty mesh. Solid splash plates shall deflect the
oil flow inside the guard in the event of the blowing of the fusible plug. The guard shall consist of a metal
plate covering the full width of the coupling, with mesh end covers to allow free flow of air. The splash
plate shall be wide enough to be able to contain all the oil on blowing of the plug.
Bolts used on guards shall be galvanized and shall not be painted afterwards to ensure easy
dismantling.
The minimum clearance between the guard and any moving parts and the size of the opening in guards
of perforated metal, woven wire, metal lattice or similar material shall be in accordance with the following
requirements:
Size of opening (mm) Minimum clearance (mm)
Not exceeding 10 20
Over 10 up to and including 15 70
Over 15 up to and including 30 100
Over 30 up to and including 40 130
These dimensions shall apply before any coating such as plastic, etc., is added to the guard.
Guards shall extend a sufficient distance to prevent any possibility of a hand being caught in the nip of
any belt, and shall extend not less than 1 000 mm from the nip point. The design of all guards will be in
accordance with the philosophy of high availability of plant and ease of maintenance. The guards shall
be easily removable and easily replaceable.

3.1.18 Fasteners

The following standards shall apply:

SABS 094, SABS 135, SABS 136, SABS 646, and SABS 1143.
Generally all black bolts shall be fitted with plain parallel washers on the underside of the nuts. In the
case of fasteners subject to vibration suitable shakeproof spring or lock washers shall be provided, or
alternatively nuts or bolts incorporating nylock locking elements.
Threaded fasteners requiring adjustment, for example, taper roller bearing applications, shall be fitted
with castellated nuts and cotter pins.
All fasteners shall be designed such that the fasteners are fully in contact with the parallel surfaces. To
achieve this, taper washers shall be used on rolled sections with taper flanges. Castings, forgings, etc.,
shall be spotfaced, counterbored or countersunk.
Hexagon socket screws shall be used in preference to slotted or cross headed screws.
Due consideration shall be given to the design of all fastened joints with regard to magnitude of
tightening torque, grade of fastener material used, and order of fastener tightening, such that distortion is
eliminated and fatigue failure does not occur.
Washers used to fasten profiled steel sections shall be tapered to prevent the bending of bolts.

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4. AUTHORISATION

This document has been seen and accepted by:

Name Designation
This Document has been approved by TDAC ROD 13 February 2013

5. REVISIONS

Date Rev. Compiler Remarks

November 2012 0 M.Masina Draft Document for review created from GGSS 0406
May 2013 1 Final Document for Publication

6. DEVELOPMENT TEAM
None

7. ACKNOWLEDGEMENTS

None

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