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TECHNICAL SPECIFICATION OF LIFE LUBRICATED IDLERS.

GENERAL
The life lubricated conveyor idlers specified hereunder shall conform to the
following minimum requirements.
1. Material handled by the conveyor: a) Iron Ore lumps upto size of 180 mm.
b) Fines and sized Iron Ore
2. Density of Iron Ore
: 2.5 MT/M.Cube
3. Maximum height of fall
: 7.25M
4. Troughing angle
: a) For carrying and impact idlers 35 degrees.
: b) For garland type return idlers 10 degrees.
5. Spacing for idler frames
: a) For carrying side 1.5 Mts. (Max)
b) For return side 3 metres
6. Conveyor belt speed
: 249 metres per minute
7. Rated capacity of conveyor
: 4000 M.T. per hour
The idlers are to be used in three roll conveyors system on the carrying sides of
conveyor or three roll/five roll garland idlers on the carrying side or two roll garland
idlers on the return side as the case may be and the idlers shall conform to the overall
limiting dimension as per the relevant drawing enclosed.
II. GENERAL SPECIFICATION OF IDLERS.
1. Specification
The idler shall confirm to this specification IS 8598 1977.
2. Protected Bearing Housing.
The idlers shall have pressed steel bearing housing with suitable sealing
arrangement, for protection against ingress of dust and moisture.

3. Precautions during assembly.


All care should be taken to avoid damage to bearing and seals in the housing
and spindle.

4. Lubrication
Idlers should have grease packed for life and grease to be of good quality,
water repellent and with high flash point

III. MATERIAL SPECIFICATION


a) Pipes
i.
ii.
iii.
iv.

The idlers shall be made using ERW pipes conforming to latest


publication of IS 9295 and its latest amendment.
Wall thickness for carrying idlers not less than 4.85 mm.
Wall thickness for return and impact idler 4.5 mm.
Co-axiality: The pipe used for manufacturing idlers shall be machined
at both ends simultaneously in one setting to maintain co-axiality.

b) Bearing Housing.
i.
ii.
iii.

Material to be used: The bearing housing shall be manufactured from


CRCA Sheet of extra deep drawing quality steel of thickness 3.5 mm.
Location: The outer edge of bearing housing shall be atleast 5 mm
away to the inside from pipe edge.
Assembly: The bearing housing shall be simultaneously welded to the
pipe at both ends to eliminate distoration. The welding equipment
used shall give smooth, continuous and strong welding so that both
housing and barrel are fused together with the required strength. The
welding shall be free from blow holes, cracks, spattering and shall be
continuous without excessive convexity.

C) Bearings.
i.
ii.
iii.
iv.

Deep groove ball bearing 6306.


Make: The bearings uses shall be SKF/FAG only.
Class C3 Standard.
Interference fit for over race M7.

D) Spindle.
i.
ii.
iii.
iv.

Material: EN9 Bright steel bar.


It shall be ground to super finish at the bearing seating with required
tolerances.
The spindle shall be of minimum diameter of 36 mm.
The spindle end shall be as shown in the relevant drawing enclosed

Seals
The idlers shall be provided with multi labyrinth seals with arrangements to prevent
ingress of dust and moisture in to the bearing housing.

IV CRITICAL DIMENSION TO BE MAINTAINED.


The dimension of idlers specified in the relevant drawing shall be strictly
adhered to. The dimensions of the nut that seats in the corresponding idler supports shall
be noted.
V. TESTING OF IDLERS.
Idlers shall be tested for the following.
a) Guaranteed friction factor not to exceed 0.015
b) Runout (Eccentricity) shall be (+ or-) 0.8 mm at any point along
the shell.
c) Dust ingression test.
d) Water ingression test.
Note: Idlers will be selected at random and the supplier shall carryout the test at his
works in the presence of Trust representatives.
VI.PERFORMANCE GUARANTEE
The life lubricated idlers shall have guaranteed maintenance free life of 5 years
from the date of supply, with a working life of not less than 25,000 hours.
VII.IDENTIFICATION OF IDLERS.
All the idlers shall be provided with proper permanent identification
mark(embossing/engraving) as approved by Port with manufacturers name, month and
year of manufacture on either side of each idler which shall not get erased during the life
of the idler.
VIII. MANUFACTURING AND TESTING FACILITIES.
The offerers shall have their own facilities for manufacturing and testing of idlers
including the following.
a)Facilities for machining both sides of pipe simultaneously
one setting to ensure concentricity.
b)Machining, grinding and drilling facilities for finishing spindles/ shafts to
close tolerance.
c)Testing facilities to test idlers for concentricity, sealing efficiency,
axials, shiftability and guaranteed friction factor etc.

in

The tenderers shall also furnish, if required by Trust, Certificate from Govt ./
Govt. approved test laboratory for all the tests specified in this specification and the
relevant standards notwithstanding this, Trust, reserves the right to carryout testing
separately.
For CONTROLLER OF STORES.

GENERAL CONDITIONS FOR CARRYING IDLER SUPPORT FRAME

1. IDLER FRAME MANUFACTURER ONLY TO BE CONTACTED.


2. THE DIMENSION OF IDLER FRAME SUITABLE FOR 1200 MM BELT
WIDTH SPECIFIED IN THE RELEVANT DRAWING NO. OH-062-78 REV.2
SHALL BE STRICTLY ADHERED TO ANY DEVIATION FROM OUR
DRAWING WILL NOT BE CONSIDERED.
3. BELT DIRECTION MARK SHOULD BE EMBOSSED/ENGRAVED AND
PAINTED IN YELLOW COLOUR IN THE RIGHT HAND SIDE OF THE
FRAME WEB.
4. THE IDLER FRAME SHALL BE PAINTED WITH ONE COAT OF ZINC
RICH PRIMER AND ONE COAT OF COAL TAR EPOXY PAINT.
5. THE FIRM MAY BE ASKED TO PRODUCE MANUFACTURERS
GUARANTEE CERTIFICATE FOR A PERIOD OF 12 MONTHS FROM THE
DATE OF INSTALLATION OR 18 MONTHS FROM THE DATE OF
SUPPLIES OTHERWISE THE SUPPLY WILL NOT BE ACCEPTED.
6. FACILITIES TO MANUFACTURE THE IDLER SUPPORT SHALL BE
FURNISHED.
7. PREVIOUS EXPERIENCES IN THE SUPPLY OF IDLER SUPPORT SHALL
BE FURNISHED.
8. MONTH, YEAR AND MANUFACTURERS NAME SHOULD BE
EMBOSSED/ENGRAVED BOLDLY LEGIBLY AND SHOULD BE VISIBLE
AT ALL TIMES.