DS SPEC 371001

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ISSUE 1 28 November 2006 Page 1 of 15



Debswana Specification

Conveyors:

Specification Requirements for Conveyor
Pulleys and Shafts

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1 SCOPE 3
2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER 3
3 DEFINITIONS 3
4 REQUIREMENTS 4
4.1 DESIGN AND DIMENSIONS 4
4.2 HUBS AND END DISKS 6
4.3 SHAFT ATTACHMENTS 6
4.4 PULLEY SHELLS 7
5 SHAFTS 7
5.2 BEARINGS AND MOUNTINGS 9
5.3 SHELL CROWNING 10
5.4 WELDING 10
5.5 STRESS RELIEVING AND NORMALISING 11
5.6 LAGGING 11
5.7 BALANCING 13
5.8 CORROSION PROTECTION 13
6 QUALITY ASSURANCE PROVISION 13
7 TEST AND INSPECTION METHODS 13
7.1 NON DESTRUCTIVE TESTING 13
8 MARKING AND PACKING 13
8.1 MARKING 13
8.2 PACKING 13
APPENDIX A : RELATED DOCUMENTS 14
APPENDIX B : RECORD OF AMENDMENTS 14
APPENDIX C : BEARING CODING 15


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1 SCOPE
This specification details the requirements for the manufacture of belt conveyor pulleys
and shafts. These pulleys are suitable for both general purpose textile reinforced belting
and steel cord reinforced belting.
2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE PURCHASER
The following requirements shall be specified in tender invitation and in orders or
contracts:
Title, reference number, issue and date of this specification.
Title(s) issue(s) and date(s) of applicable drawing(s).
Diameter, face length and hub bore of pulley and if pulley is crowned (see Clauses
4.1 and 4.6.1).
Type of lagging if required (see Clause 4.9).
The bearing code (see Appendix C)
Bearing centres of shafts. (see Clause 4.1)
Type of shaft attachment. (see Clause 4.2.1 and 4.2.2)
The name of the independent Quality Assurance Representative. (see Debswana
QAP 100)
3 DEFINITIONS
For the purpose of this specification the following definitions shall apply:
APPROVED : Approved by the Engineer in writing
BS : British Standard
DEFECTIVE : A pulley or shaft that fails to comply in one or more
respects with the requirements of this specification
PURCHASER : The Company or store designated as the recipient of
finished products or services
QUALITY ASSURANCE
REPRESENTATIVE (QAR)
: An independent inspection agency appointed and
approved by the Engineer
SANS : South African National Standards
DS : Debswana Specification
The following terms are defined in the Conditions of Contract:
Debswana, Company, Engineer, Contractor.

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4 REQUIREMENTS
4.1 DESIGN AND DIMENSIONS
The design and dimensions of pulleys and shafts shall be in accordance with the
requirements of Figure 1 and Table 1 below. In addition, when a pulley is not designed by
finite element analysis the dimensions in Table 2 shall apply.
When a pulley is designed by finite element analysis the Engineer shall approve the
analysis, pulley dimensions and manufacturing details. The minimum shell thickness in
Table 2 shall apply. The stress range in weld toes shall not exceed the values for infinite
life given in BS 7608 Fatigue Design and Assessment of Steel Structures.
4.1.1 Standard dimensions
Standard pulley dimensions are as follows:

Wide Bearing Centres
Note: Dimension A is to the inside of
the chute liners.

Narrow Bearing Centres
To be used at all locations where
chutes are not required.
Figure 1

Legend:

D Pulley face to centre-line of bearing housing
E Pulley face to belt edge
G Pulley face to inside chute plate

Note: If the required shaft diameter exceeds the allowable shaft diameter then use wide
bearing centres.
B or C B
A
G G
E E W
D D F
W
D D F

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4.1.2 Table 1 - Standard Pulley Dimensions
Bearing centres (mm)
Belt width
(mm)
Face
width
(mm)
Chute
plates I/S
(mm)
Wide Narrow
Clearances for
wide centres. (mm)
W F A B C
Max.
allowable
shaft
(mm)
D E G
450 550 650 1000 760 115 225 50 50
500 600 700 1050 810 115 225 50 50
600 700 800 1150 1020 140 225 50 50
750 900 1000 1350 1170 140 225 75 50
900 1050 1150 1550 1370 140 250 75 50
1050 1200 1300 1700 1520 140 250 75 50
1200 1350 1450 1850 1680 140 250 75 50
1350 1500 1600 2050 1830 140 275 75 50
1500 1700 1850 2300 1980 140 300 100 75
1650 1850 2000 2450 - - 300 100 75
1800 2000 2150 2600 - - 300 100 75
2100 2300 2450 2900 - - 300 100 75
2400 2600 2750 3200 - - 300 100 75
4.1.3 Table 2 - Standard Pulleys: Additional Information
End Disk
Thickness
Shaft
Diameter at
locking
element
Type of
End disk
End disk
inset
Minimum Shell
Thickness
Min Hub
Diameter
At Hub
At
Shell
50 30 14 134 25 14
65 30 14 164 25 14
75 30 14 194 30 14
90 30 18 220 30 18
100 30 18 260 32 18
120 30 18 296 32 18
130 30 18 316 40 18
140 30 22 320 40 22
150 30 22 350 40 22
160 30 22 376 40 22
180 35 22 360 50 22
200
T
u
r
b
i
n
e

35 25 420 50 25

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220 38 25 454 101 25
240 38 25 550 101 25
260 38 25 580 101 25
280 38 25 644 101 25
300
T
-
B
o
t
t
o
m

38 25 656 101 25
NOTE:
1. The minimum hub diameter is based on material with a yield stress of
0,2 =280 MPa for turbine end disks and 0,2 =270 MPa for T-bottom end disks.
2. The table is further based on Bikon 1006 (and equivalent) locking elements for
turbine end disks and Bikon 1015 (and equivalent) locking elements for T-bottom
end disks. Other locking devices may be submitted for consideration by the
Engineer, in order to maintain best practice.
4.2 HUBS AND END DISKS
Hubs and end disks shall be manufactured from steel to SANS 1431 grade 300 WA, or
350 WA, or BS 970 Part 1 grade 070M20, or cast to BS 3100 grade A2. All hubs and end
disks shall be tested prior to assembly in accordance with the method detailed in
Clause 7.1. Cracks, inclusions, blow-holes and laminations shall be cause for rejection.
Suppliers of cast hubs shall be approved. Note that cast hubs are to be considered only
for pulleys with shafts greater than 200 mm.
4.3 SHAFT ATTACHMENTS
Pulley shaft-to-hub attachments shall be by means of keyless locking elements. The
elements shall be so chosen as to be capable of transmitting the maximum torque that
can be developed by the pulley shaft.
4.3.1 When a pulley is designed by finite element analysis the calculated bending moment
applied to the locking element under start-up loads, and the angular distortion of the
locking element under start-up loads, must not exceed the recommendations of the
locking element suppliers.
4.3.2 Shrink fit shaft attachment:
While the preference is to use keyless locking elements as shaft attachments, when
shrink fit shaft attachments are specified, shafts and bosses shall be machined to BS
4500 and shall be a shaft based interference fit. Note that shrink-fit attachments will
require the approval of the Engineer.

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4.4 PULLEY SHELLS
4.4.1 Pulley shells shall be manufactured from steel that complies with the requirements of
SANS 1431 grade 300 WA or 350 WA.
4.4.2 The shell shall be machined to be concentric with the shaft within the Total Indicated Run-
out permitted in SANS 1669-1.
4.4.3 The tolerance on the pulley diameter shall be +2,0 mm. This tolerance shall be applied to
both bare and lagged pulleys.
4.4.4 For pulleys with face width suitable for belt widths up to and including 900 mm, the
tolerance on the face width shall be 3,0 mm. For pulleys with face width suitable for belt
width greater than 900 mm, the tolerance on the face width shall be 6,0 mm.
4.4.5 The shell shall have a minimum thickness after machining as indicated in Table 2.
Deviation from the minimum shell thickness after machining shall not exceed 12% of the
nominal thickness at any point on the shell.
4.4.6 The preferred shell diameters shall be limited to the range given in Table 3.
4.4.7 Other shell diameters may be submitted for consideration by the Engineer.
Table 3 - Standard pulleys: Shell Diameter

160 630 1250
200 710 1400
250 800 1600
315 900 1800
400 1000 2000
500 1120
5 SHAFTS
Table 4 - Preferred Bearing Journal Sizes
50 115 180 260
65 125 190 280
75 140 200 300
90 150 220
100 160 240
5.1.1 Shafts shall be manufactured from steel that complies with the requirements of BS 970
Part 1 grade 070M20 (EN3A). Shafting of finished diameter less than 130 mm may be
supplied as bright shafting. Shafting of finished diameter 130 mm and greater shall be
normalised. Steel conforming to grade 080M40 (EN8) and 070M55 (EN9) is not to be
used unless approved by the Engineer.

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5.1.2 Shafts shall be sized so that at all points the stresses do not exceed 90% of the yield
stress under start-up belt tensions and drive torques.
5.1.3 All contact surfaces for hub connections, bearings, seals and couplings shall be machined
round to a surface texture not rougher than R0,8 m. Undercuts, reliefs and grooves are
not permitted.
5.1.4 The bearing diameter shall be restricted to the range shown in Table 4. Where bearing
journals are smaller in diameter than that at the locking element, the shoulder at the turn-
down shall be provided with a fillet, with a radius figured at
2
) ( 3 d D
r

= or
r =(0,1d), whichever is the greater.
Here,
D = major (base) diameter
d = minor (journal) diameter
5.1.5 Where the bore of the coupling, shaft mounted reduction unit or holdback is smaller than
the journal diameter of the shaft, the shoulder at the turn-down shall be provided with a
fillet in accordance with 5.1.4 above.
5.1.6 When a pulley is not designed by finite element analysis the following rules shall be
applied, with the shaft loaded by the shear forces applied by the end discs, but ignoring
the moments applied by the discs:
The maximum allowable deflection of the shaft at the centre of the hub connection shall
be designed at 14,5 milli-radians ( 0-5-0), in accordance with the suppliers
recommendations. These deflection limits are based on the locking element types noted in
4.1.3 Note 2 above. Limits for other locking devices may be submitted for consideration by
the Engineer, in order to maintain best practice.
When the proposed design incorporates a reduction in shaft diameter, the stress factors
shall be applied to ensure that the stresses at these points do not exceed 55 MPa. All
external corners shall be chamfered to 3 mm at 45.
5.1.7 When a pulley is designed by finite element analysis the following rules shall be applied:
The minimum shaft diameter shall be calculated using the CEMA formula using the
running loads and torque. The bending moment on the locking element must also not
exceed the manufacturers maximum allowable bending moment under start-up loads
(see 4.3.1). This may require a different diameter. The maximum of these diameters shall
be used, and rounded up to the next standard diameter in Table 2.
When the design incorporates a reduction in shaft diameter the reduced diameter shall be
determined by the CEMA shaft formula, with the shaft step down concentration factors
taken into account. This diameter is to be rounded up to the next standard diameter in
Table 4.
5.1.8 Flame spraying plating, welding, stray arcing and weld spatter on shafts is not permitted.

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5.1.9 Keys and Keyways: keys and keyways shall comply with the requirements of BS 4235,
Part 1.
5.1.10 When shrink-fit shaft attachments are used, the keys shall not protrude beyond the outer
hub face. Keys and keyways for shaft extensions beyond the bearings shall be provided to
suit the attachments required for the application. See paragraph 4.3.2
5.2 BEARINGS AND MOUNTINGS
5.2.1 Bearings shall comply with the boundary dimension requirements of ISO:R15 for radial
bearings and shall be referenced by the Purchaser with the relevant Debswana code
(Appendix C).
5.2.2 Bearings shall be of the double row, self-aligning, spherical roller type 222 series for
shafts up to and including 140 mm diameter and the 231 series for shafts greater than 140
mm diameter. Bearings shall be designed for a life of 100 000 hours B10.
5.2.3 Lubrication shall be through a circumferential groove and three equally spaced holes in
the outer race. The lubricant shall be grease type GPG-2LXEP in accordance with the
requirements of Debswana standard specification 166014.
5.2.4 In all cases, the reference to bearing centres shall be construed as the centre of the
bearing housing holding down bolts, where these differ from the actual centre-line of the
bearing inside the housing. This normally applies to bearings in housings for shafts in
excess of 140 mm. The pulley manufacturer shall therefore mount the bearings on the
shafts in such a way that this requirement is satisfied.
5.2.5 Bearing housings: shall be of the horizontally split type in accordance with the
requirements of BS 5646 Part 4. Adequate sealing arrangements shall be provided.
5.2.6 Lubrication shall be facilitated by type 21A button head grease nipples in accordance with
the requirements of BS 1486 Part 2.
5.2.7 Bearing sole plates shall be in accordance with the requirements of AAC standard
drawing number Y1315.

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5.3 SHELL CROWNING
5.3.1 Crowning. (see Clause 2.3). If required, crowning shall be arranged either as
5.3.1.1 Edge-crowning, where the outer
1
/
6
of the pulley face width is tapered at a slope of 1:50,
with the centre
2
/
3
flat. The dimension at the pulley centre shall be the nominal diameter of
the pulley. The original material thickness of shell shall be sufficient to allow for machining
to end thickness dimensions as specified in Table 2.
or
5.3.1.2 Centre-crowning, where the face of the pulley is tapered at a slope of 1 : 100 with the
minor diameter at the ends of the pulley face. The dimension at the pulley edge shall be
the nominal diameter of the pulley. The original material thickness of shell shall be
sufficient to allow for machining to end thickness dimensions as specified in Table 2.
5.3.1.3 Crowning of pulleys for use with steelcord reinforced belting is generally not preferred.
See SANS 1669:1996
5.4 WELDING
5.4.1 Welding: All welds shall comply with the requirements of AWS D1.1.
5.4.2 Weld procedures shall be submitted for approval at time of tender.
5.4.3 Weld quality: Butt and fillet welds shall have complete penetration and fusion for the full
length of the weld and shall be free from undercuts, overlaps or bead surface defects.
Finished welds shall be free of cracks, porosity and inclusions.
5.4.4 Weld joint preparation. All weld joint preparation shall be available for inspection by the
Quality Assurance Representative before welding is commenced. The weld preparation
for butt welding may be modified within the limits AWS D1.1 in order to achieve full
penetration welds. Such modification shall be submitted for approval.
5.4.5 Shell butt weld method: The pulley shell butt joint shall be internally welded and shall be
dressed to a smooth profile inside and outside the shell.
5.4.6 Air vent
A 4 mm diameter air vent hole shall be provided for pulleys having either shrink fit or
keyless locking element shaft attachments in order to prevent 'blow-back' on final seal run
and distortion on vulcanising of lagging (if used). The hole shall be located outside of the
heat affected zone of the disk-to shell weld.
This hole shall be sealed with a 4 mm diameter parallel dowel pin to DIN 6325 of a length
not less than the diaphragm thickness.

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5.5 STRESS RELIEVING AND NORMALISING
NOTE
1. Details of heat treatment furnaces and recording devices shall be submitted for
approval.
2. The furnace atmosphere shall be so controlled as to avoid oxidation during the
heating and soaking periods. There shall be no direct flame on the treated article.
5.5.1 Stress relieving of pulleys shall be at a temperature of 600/650C and the heating and
cooling cycles shall be as specified in Clauses 4.8.3 and 4.8.4.
5.5.2 Normalising of shafts shall be at a temperature of 880/910C and the heating and cooling
cycles shall be as specified in Clauses 4.8.3 and 4.8.5.
5.5.3 Heating cycle: The temperature of the furnace at the commencement of the treatment
cycle shall not exceed 400C and the rate of increase in temperature above 400C shall
not exceed the following:
5.5.3.1 Not more than 200C per hour for a thickness of diaphragm plate up to and including 25
mm.
5.5.3.2 Not more than
t
5000
C/ hour for a diaphragm plate over 25 mm in thickness where
t is the diaphragm thickness in mm.
5.5.3.3 When the item has attained a uniform temperature the temperature shall be maintained
for a period of one hour for diaphragm thicknesses up to and including 25 mm. For
diaphragms over 25 mm thick allow an additional 2 minutes for each mm in thickness
above 25 mm.
5.5.4 Cooling cycle, stress relieving: The component shall be cooled in the furnace at a rate not
exceeding 250C per hour for thicknesses of diaphragm plate up to and including 25 mm.
5.5.4.1 For diaphragm plate thicknesses above 25 mm the cooling rate shall not exceed
t
6250
C /hour where t is the diaphragm thickness in mm.
5.5.4.2 Components shall be removed from the furnace at a temperature of 250C and cooled in
still air.
5.5.5 Cooling cycle, normalising: Shafts shall be cooled in still air from the maximum
temperature required in this specification.
5.6 LAGGING
See also SANS 1669-2: 2005

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5.6.1 Lagging type and pattern
The lagging pattern shall be one of the following as specified by the Purchaser.
(a) Plain Non drive bend pulleys.
(b) Chevron Direction of drive to be advised to the Contractor. Note this pattern
is not preferred.
(c) Diamond. This pattern may be used on driver pulleys and non-drive pulleys
where the contact angle exceeds 150
(d) Ceramic tiles both drive and non-drive. note that dimpled tiles are required for
drive pulleys.
5.6.2 Lagging material
The lagging material shall be one of the following as specified by the Purchaser.
(a) Natural rubber having a Shore A hardness of 65 - 70 for non flame-retardant
applications.
(b) Neoprene having a Shore A hardness of 65 + 5 for flame-retardant
applications.
The material shall comply with the requirements of Debswana specification 171001.
Other lagging materials, such as ceramic tiles, may be submitted for consideration by the
Engineer, in order to maintain best practice.
5.6.3 Lagging Thickness
The lagging thickness shall be as specified by the Purchaser and shall be not less than
10mm in the case of chevron or diamond profiled lagging.
5.6.4 Surface Preparation
The surfaces to be lagged shall be abrasive blast cleaned to SA 2 finish with a surface
profile of 40 to 65 microns in accordance with requirements of Debswana specification
164050.
5.6.5 Curing
Lagging shall be steam cured in an autoclave in accordance with the requirements of
SANS 1198.
Where the lagging is applied on site, the adhesive curing times as specified by the
suppliers shall be applied.

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5.6.6 Adhesion
An adhesion test shall be conducted on every batch of lagging material in accordance with
the requirements of SANS 1198 and SANS 1669t 2. Adhesive used shall be from the
same batch as used for the lagging process.
5.7 BALANCING
All pulleys shall be balanced in accordance with SANS 1169.
Note: Welding of fitments to the end disks for balancing purposes is not permitted.
5.8 CORROSION PROTECTION
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 20 m thickness and a single coat of
chlorinated rubber, resin based paint of not less than 30 m thickness.
6 QUALITY ASSURANCE PROVISION
The quality management system shall comply with the requirements of SABS ISO 9001.
The requirements of Debswana QAP 100 shall apply.
7 TEST AND INSPECTION METHODS
7.1 NON DESTRUCTIVE TESTING
The hubs and end disks, shell, and shaft shall be non-destructively (U/S and MPI) tested
in accordance with the requirements of Debswana specification 999001 before assembly.
Welded regions shall be re-tested after welding.
8 MARKING AND PACKING
8.1 MARKING
The following data shall be clearly and permanently marked on both vertical faces of the
shaft and on one end of the shell rim. No marking shall extend into a welded zone.
Contractor's name, trade name or trade mark.
Month and year of manufacture.
QAR's logo.
Debswana order number.
8.2 PACKING
Immediately after acceptance by the QAR, all exposed shaft surfaces shall be protected
against corrosion and accidental damage. Precautions shall be taken by the Contractor to
ensure that the pulley assemblies are not damaged during handling and transportation.

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APPENDIX A : RELATED DOCUMENTS
AAC Drawing Y1315 : Standard sole plates for conveyors (dimensions)
Debswana Specification 164/50 : Corrosion protection of steelwork with coatings
Debswana Specification 171/1 : Fire resistant elastomers for use underground in fiery mines
Debswana Specification 999/1 : Non-destructive examination for flat steel components
Debswana QAP 100 : Quality management systems for critical and major material
BS 970 Part 1 : Wrought steels for mechanical and allied engineering
purposes.
BS 3100 : Specification for steel castings for general engineering
purposes
BS 1486 Part 2 : Heavy duty lubricating nipples
BS 4235 : Metric keys and keyways
BS 4500 : ISO limits and fits
AWS/ANSI D1.1-2006 : Structural welding code - Steel
BS 5646 Part 4 : Specification for plummer block housings
DIN 6325 : Parallel pins, hardened, tolerance zone M6
SANS 1173 : General purpose textile reinforced conveyor belting
SANS 1431 : Weldable structural steel
SANS 1198 : The production and quality of rubber linings on steel pipes,
pipe fittings and vessels
SANS 1669 parts 1&2 : Conveyor Belt Pulleys
APPENDIX B : RECORD OF AMENDMENTS
Issue 0 : Based on De Beers Specification
Issue 1 : General revision. (A. Lill & G. Shortt 2006-07-14)

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APPENDIX C : BEARING CODING
Bearings listed on Debswana equipment schedules shall be coded as follows:
xxx C/T L/F (S)
Where: xxx is numeric and is the shaft diameter in mm.
C/T is either C or T and indicates whether the housing is a closed end or through
shaft.
L/F is either L or F and indicates whether the bearing is located or floating.
(S) is either present or absent and indicates whether or not a flinger ring is
required.
Example
Code 90TL indicates a bearing unit to suit a shaft of 90 mm diameter with the shaft through the
bearing and the bearing located in the housing. No flinger is required.
The locating bearing is placed at the coupling side of a through shaft, with the non-driving end
floating. Where the shaft has a double extension for a second drive, the locating bearing is placed to
best suit the arrangement. For a shaft with a double extension for a holdback device, the locating
bearing is placed at the coupling.
Pulley shaft extensions
For the range of bearings permitted by this specification, the values recommended for the extension
of the pulley shaft through the bearings of housings with closed ends are as shown in Table 5.
The dimensions shown are given from the centreline of the housing which may differ from that of the
bearing. The centreline dimension indicated on the drawing generally is that of the housing or bolt
hole centres.
TABLE 5
Shaft
dia
Bearing
code
Ext
Shaft
dia
Bearing
code
Ext
2 50 CL or F 34 150 150 CL or F 70
65 65 CL or F 42 160 160 CL or F 72
75 75 CL or F 50 180 180 CL or F 88
90 90 CL or F 55 200 200 CL or F 92
100 100 CL or F 60 220 220 CL or F 100
115 115 CL or F 68 240 240 CL or F 108
125 125 CL or F 72 260 260 CL or F 108
140 140 CL or F 85 300 300 CL or F 130