Gis 38-101

Document No.
GIS 38-101
Applicability Group
Date 30 December 2005
Guidance on Industry Standard for

Belt Conveyors, Belt Feeders, Belt Trippers
GIS 38-101
BP GROUP
ENGINEERING TECHNICAL PRACTICES
30 December 2005 GIS 38-101
Guidance on Industry Standard for Belt Conveyors, Belt Feeders, Belt Trippers
Foreword
This is the first issue of Engineering Technical Practice (ETP) BP GIS 38-101. This Guidance on
Industry Standard (GIS) is based on parts of heritage documents from the merged BP companies as
follows:
ARCO
ES 76 Belt Conveyors, Belt Feeders, Belt Trippers
Copyright  2005, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.
Page 2 of 25
Table of Contents
Page
Foreword.......................................................................................................................................... 2
1. Scope...................................................................................................................................... 5
2. Normative references.............................................................................................................. 5
3. General................................................................................................................................... 6
4. Conveyors............................................................................................................................... 6
4.1. General........................................................................................................................ 6
4.2. Idlers............................................................................................................................ 7
4.3. Pulleys......................................................................................................................... 8
4.4. Shafting (pulleys)......................................................................................................... 9
4.5. Bearings and housings...............................................................................................10
4.6. Conveyor drives.........................................................................................................11
4.7. Couplings...................................................................................................................12
4.8. Backstops or holdbacks.............................................................................................13
4.9. Brakes........................................................................................................................ 13
4.10. Access to drives and removability..............................................................................13
4.11. Lubricants................................................................................................................... 14
4.12. Wind covers and windboards.....................................................................................14
4.13. Guards....................................................................................................................... 14
4.14. Takeups..................................................................................................................... 14
4.15. Cleaners..................................................................................................................... 15
5. Belt feeders........................................................................................................................... 16
5.1. General...................................................................................................................... 16
5.2. Belt feeder frame........................................................................................................16
Page 3 of 25
5.3. Deck plate.................................................................................................................. 16

5.4. Belt feeder drives.......................................................................................................16
6. Belt conveyor trippers............................................................................................................ 16
6.1. Operating conditions..................................................................................................16
6.2. Design and construction.............................................................................................17
7. Chutes and platework............................................................................................................ 17
7.1. General...................................................................................................................... 17
7.2. Construction............................................................................................................... 17
7.3. Chute valley angles....................................................................................................18
7.4. Abrasion resistant liners.............................................................................................18
7.5. Conveyor skirtboards and skirts.................................................................................18
7.6. Deck plates and protection at road crossings.............................................................19
7.7. Drip pans and covers.................................................................................................19
8. Structural steel for conveyors................................................................................................20
8.1. Design loads..............................................................................................................20
8.2. Design considerations................................................................................................20
8.3. Design basis............................................................................................................... 21
8.4. Materials..................................................................................................................... 21
9. Control devices...................................................................................................................... 22
9.1. Emergency stop switches...........................................................................................22
9.2. Low speed switch.......................................................................................................22
9.3. Side travel switches....................................................................................................22
9.4. Plugged chute detectors.............................................................................................22
10. Other requirements............................................................................................................... 22
10.1. Calculations................................................................................................................22
10.2. Belting........................................................................................................................ 23
10.3. Welding...................................................................................................................... 23
10.4. Diverter gates.............................................................................................................23
11. Assembly............................................................................................................................... 23
12. Tests and inspections............................................................................................................ 24
13. Installation checklist.............................................................................................................. 24
14. Spare parts............................................................................................................................ 24
15. Material safety data sheets (MSDS)......................................................................................25
Page 4 of 25
1. Scope
This GIS provides guidance on industry standard for design and fabrication, inspection and testing,
documentation, and installation of belt conveyors, belt feeders, belt trippers, and associated
equipment.
2. Normative references
The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For dated references, subsequent amendments to, or
revisions of, any of these publications do not apply. However, parties to agreements based on this
technical practice are encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references, the latest edition of the normative
document referred to applies.
American Institute of Steel Construction (AISC)

AISC 101 Designing with Structural Steel - A Guide for Architects.
American National Standards Institute (ANSI)

ANSI B3.15 Life of Ball Bearings.
ANSI B3.16 Life of Roller Bearings.
ANSI B105.1 Welded Steel Conveyor Pulleys with Compression Type Hubs.
American National Standards Institute (ANSI) / American Gear Manufacturers

Association (AGMA)
ANSI / AGMA 6010-F97 Standard for Spur, Helical, Herringbone, and Bevel Enclosed Drives.
American National Standards Institute (ANSI) / National Fluid Power Association

(NFPA)
ANSI / (NFPA) T3.16.2 Hydraulic Fluid Power - Design for Nonintegral Industrial Reservoirs.
American Society for Testing and Materials (ASTM)

ASTM A36 Standard Specification for Carbon Structural Steel.
ASTM A235 Specification for Carbon Steel Forgings for General Industrial Use.
American Welding Society (AWS)

AWS A5.1 Specification for Carbon Steel Electrodes for Shielded Metal Arc
Welding.
AWS A5.17 Specification for Carbon Steel Electrodes and Fluxes for Submerged Arc
Welding.
AWS A5.18 Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc
Welding.
AWS D1.1 Structural Welding Code Steel.
BP Engineering Technical Practices (ETPs)

GP 12-45 Guidance on Practice for Electrical for Packaged Systems
GP 60-50 Guidance on Practice for General Issues-Equipment Packages
Page 5 of 25
Conveyor Equipment Manufacturers Association (CEMA)

CEMA, Belt Book Belt Conveyors for Bulk Materials (Sixth Edition).
International Code Council (ICC)

IBC International Building Code-Includes Erratas Updated 11/03/03; 4/2004;
5/2004; 8/12/04; 12/2004; 01/2005.
3. General
a. Equipment shall be suitable for outdoor or indoor installation as specified.

b. Materials and components shall be shipped in maximum sizes consistent with delivery
restriction.
c. Shop assembly shall be to maximum extent to minimize field erection or installation.
d. Unless specifically stated otherwise in the procurement documentation, the electrical
components shall conform to the requirements in GP 12-45.
e. Quotation shall comply with this standard. Alternate quotations may be submitted,
provided the following two conditions are met:
1. Significant process, price, or delivery advantage is indicated, or a superior product is
offered at a justifiably higher price, or a product of equal quality is offered at a lower
price.
2. Alternate quotation states deviations from this GIS, and complete engineering details
of alternate material and/or design are submitted for BP review.
f. Deviations between this GIS and other contract or procurement documents, unless
specifically indicated as an exception, shall be submitted to BP for written ruling.
g. Company and supplier shall determine the applicable requirements in GP 60-50 to be
followed and include those as part of the procurement documentation.
4. Conveyors
4.1. General
a. Conveyors and components shall be manufacturer’s normal design for specified service.
b. Standard replacement parts shall be available in 60 days or less.
c. Unless specified otherwise, design shall be based on standards adopted by CEMA.
d. BP design parameters indicated on data sheets shall be verified.
e. Selected conveying equipment shall be suitable for service and capacities specified.
f. Drives and conveyor components shall be sized to start conveyor under full belt load
condition.
g. Conveyors with vertical concave curves shall be designed to prevent belt lift off under
empty, loaded, or partially loaded condition.
h. Head pulleys shall be raised above contact line between conveyor belt and centre idler roll
to one half of full trough depth.
Page 6 of 25
4.2. Idlers
4.2.1. General
a. Unless specified otherwise, idlers shall be:
1. “Prelubricated,” factory sealed for life, ball or roller bearing type belt conveyor idlers
CEMA series rated.
2. Identified by manufacturer brand name and model number.
b. Roller ends shall be smooth and free of sharp edges and burrs.
c. Idler rolls shall be fitted with end shields to protect bearings and seals.
d. Seals shall be suitable for taconite type service.
e. Idler bearing ratings shall comply with ANSI B3.15 and B3.16.
f. Lubricated idlers, if specified, shall be equipped for one side through lubrication using
standard 16 mm (5/8 in) diameter “button head” type lubrication fittings.
g. Minimum L-10 life rating shall be 60,000 hours at conveyor rated capacity and speed.
h. Idlers mounted under skirtboards shall be designed so that they can be removed or replaced
without interference or dismantling of skirts, chutes, or frame.
4.2.2. Troughing idlers

a. Troughing idlers shall be three roll type, with end and centre rolls interchangeable.
b. Troughing angle shall be as specified on conveyor data sheets.
4.2.3. Training idlers

a. Training idlers shall either be:
1. Positive action type, with ball bearing actuated rollers mounted on both ends of idler
bracket that shall be free to swivel about vertical pivot on base.
2. Actuating disc type, which can be used if belt lift might occur as on conveyors with
concave curves.
b. Conveyors with fabric belt, conveyors with flat return idlers, and conveyors that are 24 m
(80 ft) or longer shall have training idlers.
c. Training idlers shall be placed within 15 m (50 ft) of both head and tail pulley and at no
more than 45 m (150 ft) centres, with minimum of two per conveyor.
d. Training idlers shall not be located under skirt boards.
4.2.4. Return idlers

a. Return idlers shall have same bearings as troughing idlers.
b. Unless specified otherwise, return idlers shall have standard drop bracket.
c. Return idlers shall be solid roll or self centring spiral roll as specified on conveyor data
sheets.
d. Spiral return rollers shall be used if conveying material, e.g., wet green coke, can
agglomerate to solid return rollers and lead to misalignment.
e. Load rating shall be such that removal or destruction of any single return idler does not
cause failure of adjacent idlers.
f. Closer idlers shall not be used in lieu of snub pulley.
Page 7 of 25
4.2.5. Impact idlers

a. Impact idlers shall be rubber cushion type, with troughing angle.
b. Idler assemblies shall be mounted such that they can be removed without interference with
skirts, chutes, or frame.
c. Impact idlers shall not be required for handling green coke and calcined coke unless
vertical drop is more than 240 cm (8 ft) Instead, regular troughing idlers (in accordance
with b.) at 30 cm (12 in) spacing shall be provided.
4.2.6. Transition idlers

a. Rigid frame transition idlers shall be adjustable troughing angle type, adjustable in
approximately 2,5 degree angle increments.
b. Rigid frame transition idlers shall be provided in locations where conveyor belt changes
from flat to trough and vice versa, i.e., at head and tail ends of troughed conveyors.
4.2.7. Picking idler

a. Picking idlers shall be used on belt feeders outside of hopper opening.
b. Picking idlers shall have troughing angle as shown on feeder data sheet.
4.2.8. Belt scale idlers

a. Belt scale idlers shall have inline troughing rolls and shall comply with belt scale
manufacturer specifications.
b. Idlers shall be colour coded for easy identification.
4.2.9. Idler spacing

a. Idler spacing shall be such that idler load rating is not exceeded.
b. Maximum belt sag on carrying run shall not exceed 2% of idler spacing if running with full
belt load condition.
4.3. Pulleys
4.3.1. Loads
Pulley loads shall be determined from larger of either tension developed using connected motor
kW (hp) or 75% of tension developed during acceleration.
4.3.2. Lagging
a. Pulley lagging shall be vulcanized to pulley. Drive, snub, and bend pulleys shall be lagged
as a minimum.
b. Crowning of pulleys by varying thickness of lagging shall not be acceptable.
c. Lagging for driven and nondriven pulleys shall be 19 mm (3/4 in) thick diamond grooved.
Grooves shall be 9 mm (3/8) in deep by 9 mm (3/8 in) wide on 63 mm (2 ½ in) centres.
4.3.3. Assemblies and shipping

a. Pulley assemblies, including pillow blocks and coupling halves, shall be completely shop
assembled and mounted on support frame.
b. Critical dimensions shall be verified.
c. Motions shall be checked and tested in shop prior to shipment.
d. Pulley assemblies shall be shipped as complete unit.
Page 8 of 25
4.3.4. Standardisation
a. “Pulley assembly” shall be unique assembled combination of pulley, shaft, and bearings.
b. Each belt width shall be limited to three pulley sizes.
c. Pulleys of given “pulley assembly” shall be interchangeable with all other pulleys of that
design.
d. Pulleys shall comply with tolerances and load rating specified in ANSI B105.1.
e. Face width of pulleys for fabric belts shall be 100 mm (4 in) wider than belt width.
f. Pulleys shall be crown or straight face. Crown face pulley shall have taper of 5 mm per
meter (1/16 in. per ft ) of pulley width.
g. Pulleys shall have compression or expansion type hubs. Pulleys shall have one key in each
hub.
h. Concentricity about shaft centreline shall be such that total indicator runout shall not
exceed the following:
1. Pulleys 150 mm (6 in) to 400mm (16 in) diameter – 1,5 mm (1/16 in) before lagging
2 mm (5/64 in) after lagging.
2. Pulleys 457 mm (18 in) and over diameter – 3 mm (1/8 in) before lagging, 3,5 mm
(9/64 in) after lagging.
4.4. Shafting (pulleys)
4.4.1. Turned down shaft ends

a. Turned down shaft ends shall have finish of 0,8 mm (32 micro in) or better and shall be
liquid penetrant tested for flaws after machining.
b. Turndown radii shall be not less than 25% of minor shaft diameter.
c. Turndown radii shall have 1,6 mm (63 micro in) finish or better.
d. End turndown on shafts under 152 mm (6 in) diameter is undesirable and shall be
permitted only for consolidation of bearing sizes and fitting shaft mounted reducers.
4.4.2. Shear stress

a. Shear stress in combined bending and torsion of commercial AISI 1045 steel shafts shall
not exceed 552 hPa (8,000 psi) for shafts with keyways or 735 hPa (10,667 psi) for shafts
without keyways.
b. Shear stress in combined bending and torsion for other grades of steel shall not exceed
14% of ultimate tensile strength for shafts with keyways or 18% of ultimate tensile
strength for shafts without keyways.
4.4.3. Bending stress

a. Bending stress for commercial AISI 1045 steel shafts subject to bending only shall not
exceed 827 hPa (12,000 psi) for shafts with keyways or 1,103 hPa (16,000 psi) for shafts
without keyways.
b. Bending stress for other grade steel shafts subject to bending only shall not exceed 28%
percent of ultimate tensile strength for shafts with keyways or 36% of ultimate tensile
strength for shafts without keyways.
4.4.4. Service factor

a. Combined shock and fatigue service factor of Kb=1.75 shall be applied to computed
bending moment.
Page 9 of 25
b. Service factor of Kt=1.25 shall be applied to computed torsional moment of shafts used
with standard pulleys.
4.4.5. Slope
Slope, in radians, of shaft deflection curve at pulley hubs under pulley design load conditions
shall not exceed 0,0015 radian (0.086 degrees).
4.4.6. Shaft diameters

Formulae used for computing shaft diameters shall be as specified.
4.5. Bearings and housings

a. Pillow blocks, flanged units, and takeup units shall have double roller, fully self aligning,
bearings with adapter sleeve mounting.
b. Misalignment shall not be limited by seal.
c. Each pulley shaft shall have one fixed and one expansion type bearing, fixed bearing being
on drive end of any driven shaft.
d. Grease fittings
1. Bearings shall have provisions for grease lubrication and be fitted with taconite seals.
2. Unless specified otherwise, grease fittings shall be standard 16 mm (5/8 in) diameter
button head type for grease gun lubrication.
3. If access is limited, grease lines shall be extended to location where they can be
grouped for ease of regreasing.
4. Taconite seals shall have their own grease fittings and have same access as specified
in 2.
5. Takeup pulleys that are not accessible from walkways shall have lubrication points
accessible from walkway.
6. Tubing shall be made of stainless steel.
7. If flexibility is required, e.g., takeup pulleys, rubber tubing should be used.
e. If shafts terminate at bearings, housings shall have dust tight end discs.
f. Pillow blocks
1. Pillow blocks shall have horizontally split housings.
2. Pillow blocks larger than 62 mm (2 7/16 in) shall have four bolt bases. Bolts shall
have self locking nuts or shall have two nuts per bolt.
3. Bearings shall be specified in 12 mm (1/2 in) increments starting from 11 mm (7/16
in).
4. Required mounting of pillow blocks shall be on top surface of supporting steel.
Suitable adjusting screws and lugs shall be welded to supporting steel to facilitate
alignment of components.
5. Pillow blocks provided for pulleys shall have shim sets, consisting of three 3 mm (1/8
in) thick and two 1.5 mm (1/16 in) thick stainless steel shims.
6. Pillow blocks mounted in vertical or suspended position shall be subject to BP written
approval.
g. Life rating
1. Bearing L-10 life rating shall comply with ANSI B3.16.
Page 10 of 25
2. Minimum L-10 life rating shall be 60,000 hours at rated capacity and speed.
4.6. Conveyor drives

a. Conveyor drives shall be located for ease of access and maintenance.
b. Conveyor acceleration torque shall not exceed 150% of rated tension under any loading
condition.
c. Flywheels and brakes shall be provided as required to control coasting distances.
d. Conveyor drive units shall be of sufficient capacity to start and stop belts under maximum
loading conditions. Parts shall be standardized for interchangeability.
e. Helical gear reducers
1. Shaft mounted helical gear reducers with torque arm shall be provided for drives up
to 76 hp metric (75 hp electric), with cog belt reduction to pulley shaft.
2. Shall have helical gear parallel shaft directly coupled to motor and pulley shaft
through fluid coupling.
3. Each shaft mounted reducer shall have adjustable motor mount or common structural
base.
4. Baseplate mounted drive components shall have suitable adjusting screws and lugs
attached to baseplate to facilitate aligning of components.
5. Torque arms (turnbuckles) may only be provided if loaded in tension.
f. Cog type belt drives
1. For cog type belt drives, motor mount shall be adjustable.
2. Minimum service factor of 150% based on motor nameplate hp metric (hp electric)
shall be used on all cog belts.
3. Sheaves shall be made of steel and have demountable, compression type hubs keyed
to shafts.
4. For timing belt speeds between 1 219 and 1 524 m/min (4,000 and 5,000 ft/min),
sheaves and hubs shall be statically balanced.
5. For belt speeds above 1 524 m/min (5,000 ft/min), dynamically balanced sprockets
shall be provided.
g. Mechanical rating
1. Mechanical hp metric (hp electric) rating of gear reducers shall be based on service
factor of 150% connected motor hp metric (hp electric) rating.
2. Mechanical rating shall permit overloads of 275% of connected motor torque rating,
during momentary peak loads not exceeding five peaks per hour.
h. Thermal rating
1. Thermal rating of reducers shall not be less than connected motor hp metric (hp
electric) under continuous duty.
2. Use of auxiliary oil or water cooling systems to achieve thermal hp metric (hp
electric) rating shall not be permitted.
3. Reducer bearings shall be antifriction type with minimum L-10 life rating to 60,000
hours.
i. Gears shall be designed and manufactured to latest edition of ANSI / AGMA 6010-F97,
with service factors applied to motor nameplate hp metric (hp electric).
Page 11 of 25
j. Durability
1. Each gear set shall have AGMA durability of not less than 1,5 and AGMA strength
rating of not less than 150% durability rating.
2. If case hardening is used for gears, carbonizing process shall be used.
3. Induction hardening shall not be allowed.
k. Finish machining and profile grinding
1. Finish machining and profile grinding shall be performed after heat treatment and
hardening is complete.
2. Hobbing process shall preferably be used to cut gear tooth profiles.
l. Reducer housings
1. Reducer housings shall be steel and have oil filler plug, oil drain plug, oil level
indicator, i.e., sightglass, and breather with provision for exclusion of dust.
2. Shafts that project through housing shall have flushable external combination grease
and contact or taconite type labyrinth seal with separate grease fittings.
m. Reducers lubrication
1. Reducers shall be splash lubricated.
2. Cooling of reducer, if required, shall be accomplished by reducer driven fans only.
3. Maximum operating oil temperature of the reducers shall not exceed 88°C (180°F).
4.7. Couplings
a. Couplings shall be designed and constructed with service factor of not less than 150% for
high speed shaft and low speed shaft couplings based on connected nameplate hp metric
(hp electric).
b. Low speed and high speed couplings shall be The Falk Corporation “T Grid” type or
approved equal.
c. Conveyors with concave curves
1. Conveyors with concave curves shall have delayed fill fluid coupling to permit
smooth starting of conveyor.
2. Coupling slip shall be limited to maximum of 4% at full load torque and motor speed.
3. Couplings shall be capable of manual adjustment in field between 140% and 160% of
demand hp metric (hp electric).
4. Hydraulic systems shall be designed in accordance with ANSI / (NFPA) T3.16.2.
5. Fire resistant fluids shall only be used if specified in applicable equipment
specification.
6. If required, hydraulic systems shall have adequate provision for cooling and/or
heating to ensure proper operation under continuous duty at specified extreme
ambient temperature conditions.
d. Coupling guards
1. Non sparking coupling guards, 1,5 mm (1/16 in) minimum thickness, solid plate (not
open mesh) construction, shall be provided.
2. Guards shall be designed in accordance with OSHA regulations and local and state
laws prevailing at installation site.
3. Shaft coupling guards shall extend to within 12 mm (1/2 in) of stationary housings.
Page 12 of 25
4. While being firmly attached to baseplate, guards shall be easily removable and
sufficiently rigid to withstand deflection and prevent rubbing as a result of bodily
contact.
5. Vendor standard coupling guard may be used if substantially in accordance with
requirements in this GIS.
6. Bolts and screws, if used, shall be M9 (3/8 in) nominal diameter.
4.8. Backstops or holdbacks

a. Ascending conveyors shall have holdbacks of adequate capacity to prevent reversal of
conveyor if stopped under full design load.
b. Except for conveyors with long horizontal or declined sections, selection of holdback shall
be based on stalled torque rating of drive motor.
c. Holdbacks shall have taconite seals.
d. On conveyors with drives of 101 hp metric (100 hp electric) and larger, holdbacks shall be
mounted on pulley shaft opposite drive and shall be overrunning clutch type.
e. Conveyors with drives less than 101 hp metric (100 hp electric)
1. For smaller drives, less than 101 hp metric (100 hp electric), sprag type holdbacks
may be installed on high speed shaft of speed reducer.
2. Holdbacks shall be readily accessible for maintenance and replacement.
3. Holdbacks mounted on reducer low speed shaft shall have suitable reverse torque
reaction arm of quick change type with pin connection and keys and bored to size.
4. Torque restraining arm shall be restrained by reducer baseplate.
5. Each holdback shall have inboard and outboard steel safety set collars to restrict axial
movements.
4.9. Brakes
a. Coasting time control brakes, including brake wheels, shall be provided between motor
and reducer, if required.
b. Braking systems shall be supplied on conveyors that cannot come to a stop under
emergency conditions without overfilling discharge chute or downstream conveyor.
c. Brakes shall be:
1. Spring set double shoe type, adjustable for breaking effort.
2. Thruster or solenoid release type.
d. Brake enclosure shall be NEMA type 4.
e. Brakes shall have sufficient heat dissipating capacity to allow four stops per hour
minimum or number of stops that operation requires.
f. Brake service factor shall be 1.5 based on full load motor torque.
4.10. Access to drives and removability

a. Service platforms shall have 1 m (36 in) minimum clearance around all equipment.
b. All mechanical equipment shall be readily removable without dismantling any steel work.
Page 13 of 25
4.11. Lubricants
a. Lubricants shall be compounded such that they perform intended function under specified
weather conditions. This applies to both shop and field lubricated items.
b. Lubrication compound recommended for type and quantity of lubricant and lubrication
interval schedule for equipment furnished for storage and operating condition shall be
provided.
4.12. Wind covers and windboards

a. Outdoor conveyors shall have wind covers.
b. Covers shall be located over carrying belt, with 38 cm to 53 cm (15 in to 21 in) opening on
walkway side.
c. Covers shall be designed and fabricated in sections that can be hinged open and closed
without need of tools.
d. Each section shall include stop to limit cover movement in open position.
e. Wind covers shall be noncorrosive or protected to prevent corrosion in specified
environment.
f. Other designs to accomplish environmental protection functions of wind covers may be
submitted for company consideration.
g. Conveyor covers shall be designed to permit equipment lubrication, if required, without
cover removal.
4.13. Guards
a. In addition to safety devices and guards specified elsewhere, expanded metal guards shall
be provided at all nip points on conveyor.
b. Guards shall be designed to allow lubrication of equipment without removal or opening of
guards.
c. Guards shall be provided in accordance with OSHA regulations.
d. Guards shall be fitted with handles to aid in their removal.
e. Guards shall have sheet metal top and expanded metal sides.
4.14. Takeups
4.14.1. Screw takeups

a. Screw takeups are acceptable only on belt feeders with length less than 30 m (100 ft)
between head and tail pulleys.
b. If used, takeups shall:
1. Be protected screw type.
2. Be roller bearings.
3. Comply with all requirements of 4.5.
4. Screw takeup length shall be a minimum of 61 cm (24 in).
4.14.2. Vertical gravity takeups

a. All other conveyors shall have vertical gravity takeups.
b. Takeups shall include counterweight box that will be filled with concrete by BP.
c. Concrete level shall be indicated by Vendor.
Page 14 of 25
d. Vendor shall provide 25% more room for additional weight to be added later if needed.
e. High overhead counterweights shall be avoided by use of suspension cables.
f. Safety guards or fences shall be provided to close off areas immediately under
counterweight.
g. Counterweight load shall be provided on stainless steel tag permanently attached to box.
h. Overflow weep holes shall be provided in box to permit water drainage.
i. Vertical gravity takeups shall employ dribble deflector canopy to prevent debris from
falling onto takeup pulley.
4.14.3. Tail pulley takeups

a. Tail pulley takeups, whether screw or gravity type, shall be designed to accommodate
minimum of 2% belt stretch.
b. Design consideration shall be given to locating takeup to accommodate vulcanized belt
resplice.
4.14.4. Counterweight safety cages

a. Counterweight safety cages shall be located at floor or grade level.
b. Cages shall be made of expanded metal weighing not less than 18 kg per 30 m 2 (40 lb per
100 ft2) mounted on structural frame.
c. Expanded metal panels shall be 210 cm (7 ft) high and shall be set 50 cm (1 ft 6 in) above
concrete foundation or floor elevation.
4.14.5. Rope and sheaves

a. Wire rope shall be flexible steel core hoisting rope, with minimum breaking strength of six
times maximum calculated working load.
b. Rope ends shall be fastened with clips sufficient to develop full breaking strength of rope.
c. Sheaves shall be steel, cast iron, or cast steel with “lubrite” bushing or equal mounted on
dead shafts.
d. Sheave diameters shall be a minimum of 20 times wire cable diameter.
4.15. Cleaners
4.15.1. Scrapers
a. Belt conveyors shall have scrapers to clean carrying side of belt at head pulley.
b. Cleaning system will be specifically stated on data sheets for unique material conveyed.
No substitutions shall be accepted.
c. Belt cleaner access for adjustment and replacement shall be provided to prevent shutting
conveyor down.
4.15.2. Return run plows

a. Return run plows shall be either:
1. “V” type return over full belt width, extended 100 mm (4 in) minimum over each
side.
2. Straight edge type positioned at π/4 radians (45 degrees) shall be provided.
b. Plows shall be just clear of return strand of belting and immediately ahead of bend, takeup,
and tail pulleys, where material can be caught between belt and pulley.
Page 15 of 25
c. Plows shall be mounted such that steel cannot contact belt after wiper rubber has
completely worn down.
d. Plows shall have vertical adjustment and safety chain to prevent plow from travelling with
belt in case of failure of mounting.
e. Scraper rubber hardness shall be durometer (Shore A) of 60-80.
f. Minimum thickness of rubber blade shall be 25 mm (1 in).
g. Plow shall be designed to perform effectively as it wears.
5. Belt feeders
5.1. General
a. Belt feeder components shall be manufacturer’s heavy duty design.
b. Replacement parts shall be readily available.
c. Flow from hopper discharge opening shall be regulated by slide gate or automated feeder
mounted to open in line with conveyor belt travel.
d. Loading trough knife gates shall not be used for flow regulation.
e. Belt feeder components shall be as specified for belt conveyors in 4, except that face width
of pulleys shall be 150 mm (6 in) wider than belt width.
f. “V” type return plows are not required on feeders.
5.2. Belt feeder frame

Feeder frame shall be steel stringer construction with suitable diagonal and cross bracing and
supporting legs or hangers.
5.3. Deck plate

a. Steel plate decking shall be:
1. 3 mm (1/8 in) thick suitably reinforced on bottom side.
2. Provided between carrying and return belt.
b. Deck plate shall end 50 mm (2 in) from pulleys.
5.4. Belt feeder drives

a. Feeders shall have AC drive.
b. Drives of belt feeders located below silos shall have sufficient capacity to start belt under
maximum loading and with full material load in and above transfer chute.
c. Drives of belt feeders located below auxiliary hoppers shall have capacity to start conveyor
with maximum loading and with full material load in auxiliary hopper.
6. Belt conveyor trippers
6.1. Operating conditions

Tripper shall be capable of discharging while travelling in forward or reverse direction and shall
be capable of being locked in any location for spot discharge.
Belt conveyor tripper is used to remove material from belt conveyor and stack it in a
pile that extends length of tripper travel.
Page 16 of 25
6.2. Design and construction

a. Tripper shall be manufacturer’s normal design for service specified.
b. Frame shall be of rigid welded and bolted construction, providing adequate accessibility
for maintenance.
c. Construction shall permit easy removal of pulleys and wheels.
d. Wheels shall be double flanged with hardened rims.
e. Wheel drive shall consist of gear reducer with enclosed roller chain drive.
f. Drive shall have magnetic brake capable of stopping and holding tripper.
g. Tripper shall have hand operated rail clamps.
h. Drive shall be mounted opposite from platform.
i. Single speed drive shall be supplied to propel tripper at speed of 6 m (20 ft)/min.
j. Tripper shall be reversible within set limits of travel.
k. Operator platforms and access ladders shall be:
1. Furnished on both sides of tripper.
2. Connected such that operator can cross from one side to other.
l. Walkways shall be provided on one side of inclined belt for access to idlers and pulley
bearings.
m. Platforms and stairs shall be of bar grating.
n. If economically advantageous, walkways may be provided with expanded metal having
minimum weight of 6 kg/m (4 lb/ft).
o. Festooned systems shall have power and control cable. Steel for festoon cable supports
shall be provided.
p. Other components of tripper shall comply with this GIS.
7. Chutes and platework
7.1. General
a. Unless specified otherwise, chutes, skirtboards, and skirtboard supports from conveyor to
conveyor or from conveyor to mating flange of BP equipment shall be provided.
b. BP equipment mating flange details will be provided to Vendor.
7.2. Construction
a. Chutes shall be:
1. Fabricated from 6 mm (1/4 in) ASTM A36 steel, with necessary stiffeners.
2. Commercially dust tight design.
b. Chute corners shall be made dust tight by continuous welds.
c. Chutes shall be of welded construction with bolted flanges and bolted to their respective
supporting frames.
d. Chutes shall be designed for easy maintenance.
e. Field and shop bolted connections shall have BP approved gaskets.
f. Rock boxes
Page 17 of 25
1. Rock boxes shall be provided to break horizontal and vertical velocity of flow and
direct material towards centre of discharge chute or downstream conveyor belt
between skirt boards.
2. If places where certain conveyed materials may tend to build up at rock boxes and
choke chute, low sliding resistance liners, e.g., 6 mm (1/4 in) thick 304 SS, should be
used in lieu of rock boxes.
3. If trajectory of material is unknown or complex, manually adjustable abrasion
resistant lined deflector plates shall be required to provide centre loading of material
on belt.
g. Head chutes
1. Head chutes shall be designed to allow easy removal of head pulley and belt cleaners.
2. Head chute shall be sized large enough to fully collect belt cleaner scrapings and
deposit them onto next belt in system.
3. Inside chute width at discharge pulleys shall be pulley face width plus 75 mm (3 in)
minimum to prevent belt edge damage due to belt misalignment.
4. Discharge chute top covers shall be made of 5 mm (3/16 in) thick mild steel with
suitable stiffeners.
5. Discharge chute entrance shall have dust curtain.
6. Head chutes shall have minimum 610 mm (24 in) square cleanout and inspection
door, latched and hinged (not bolted), which opens to side.
7. Door opening on head chute cover door shall have greater clear width than belt width.
8. Head chutes equipped with radiation sources shall have grating type door with lock
behind M10 inspection door to allow inspection without radiation device lockout.
h. Conveyors shall have material distribution chute (bootjack) insert at all loading points to
enhance transfer of material from vertical motion to horizontal.
7.3. Chute valley angles

a. Chute valley angles shall be minimum 0,96 radian (55 degrees) from horizontal.
b. If required, angle shall be increased to ensure material flow.
7.4. Abrasion resistant liners

a. Abrasion resistant liners shall be used on surfaces if abrasive material in movement
contacts chutes, hoppers, and skirtboards.
b. Individual liners shall:
1. Weigh 45 kg (100 lb) maximum.
2. Be minimum of 12 mm (1/2 in) thick.
3. Be fastened with minimum of four bolts.
c. Liner material shall be abrasion resistant plate with minimum 400 BHN (Brinell hardness
number).
d. Liners shall be fastened with 16 mm (5/8 in) countersunk cap screw, with hex head nut and
lockwasher.
7.5. Conveyor skirtboards and skirts

a. Skirtboards shall be:
Page 18 of 25
1. Designed to allow smooth flow of material.

2. Of ample depth (typically 2/3 to 3/4 of belt width).
3. Fabricated of 6 mm (1/4 in) ASTM A36 steel for conveyors.
4. Of bolted construction.
5. Designed for easy maintenance.
b. Skirtboards shall have 12 mm (1/2 in) thick minimum abrasion resistant liners and be
mounted 6 mm to 9 mm (1/4 in to 3/8 in) above belt in loading areas.
c. Inside liner shall be flush throughout its length with no steps or spaces.
d. Skirtboards shall have adjustable 12 mm (1/2 in) thick rubber sealing strips of 55 to 60
durometer hardness.
e. Adjustable sealing systems, such as Asgco or Flexiskirt , shall be provided.
f. Minimum skirtboard lengths shall be identified in project specifications.
g. Skirtboard enclosures shall have shovel box.
h. Skirtboard covers shall be 5 mm (3/16 in) mild steel with suitable stiffness.
i. Skirtboard exits shall have rubber dust curtains to contain dust.
7.6. Deck plates and protection at road crossings

a. Conveyors shall have decking between carrying and return belt at loading points starting:
1. 50 mm (2 in) away from tail pulley to 450 cm (15 ft) past end of skirt board.
2. At gravity takeup, 6 m (20 ft) on either side of gravity takeup.
3. At horizontal takeup over complete length of takeup plus 450 cm (15 ft) on either side
4. At head end, 50 mm (2 in) away from head pulley to 6 m (20 ft) away from pulley.
5. Over roads plus 3 m (10 ft) on either side.
b. Deck shall be a minimum of 3 mm (1/8 in) thick steel adequately stiffened on bottom of
deck plate.
c. If conveyors cross roads, bottom of truss shall have bars, screen, or other protection to
prevent return idlers mounted on elevated structure from falling to ground below.
7.7. Drip pans and covers
7.7.1. General
Drip pans, if specified, shall cover full length of conveyors and comply with geometry depicted
in graphic standard.
7.7.2. Flanged drain connections

Flanged drain connections, 200 mm (8 in), shall be provided for BP piping at 30 m (100 ft)
maximum intervals or upstream of every drip pan break.
7.7.3. Drip pan covers

a. Drip pan covers are required with conveyed materials that require dust collection systems.
b. Drip pan covers shall be designed for ease of removal, i.e., hand removal of one cover at a
time by one person.
c. Sequential removal requirement to access a particular cover shall not be permitted.
Page 19 of 25
8. Structural steel for conveyors
8.1. Design loads

a. Dead loads (DL) shall denote weight of fixed structural elements.
b. Equipment loads (DLe) shall be loads of fixed equipment, conveyors, etc., without
contents.
c. Live loads (LL) include floor area loads, weight of material in transit, snow load, wind
load, etc.
d. In no case shall minimum design live loads be less than specified in e.
e. The following are material weights for use in computing live loads (for other materials, BP
shall be consulted):
Material Bulk density Angle of repose
Green coke feed from coker (undrained) 28.5 kg per 0.3m3 0.645 radian
(63 lb/ft3) (37 degrees)
Green coke from green coke storage building (drained) 25.4 kg per 0.3m3 0.645 radian
(56 lb/ ft3) (37 degrees)
Calcined coke 21.3–24 kg per 0.3m3 0.61 radian
(47-53 lb/ft3) (35 degrees)
f. The following minimum live loads shall be used in design. Except as indicated, loads will
be in kg per 0.3m2 (pounds per square foot) of horizontal projection. Certain other
applicable loads are listed separately in succeeding sections.
Roofs (snow) SL 9 kg per 0.3m2 (20 psf)
Stairs and walkways 45 kg per 0.3m2 (100 psf)*
Conveyor gallery walkways 23 kg per 0.3m2 (50 psf)**
Railings 90 kg (200 lb) applied in any direction at top of railing
* Or a concentrated load of 300 lb placed at centre of tread.
** This live load shall be used for designing those elements directly supporting walkway.
g. Live load reduction shall comply with ICC.

h. Design live loads
1. In loading combinations, including earthquake motions, design live loads (LLo) shall
be limited to live load during operation, which is defined as live load expected to be
present if plant is operating.
2. “LLo” shall be established in accordance with layout and mechanical requirements.
3. Those loads include contents of fixed equipment, plugged chutes, etc.
i. Wind loads
1. Wind load (WL) calculations shall be based on basic wind speeds valid for equipment
location.
2. Wind forces shall be computed in accordance with local standards.
j. Structures shall be designed for seismic loads (EL) determined in accordance with local
standards.
8.2. Design considerations

a. Equipment support structure and elements shall be designed to accommodate loads or
effects produced by thermal expansion.
b. Trusses and supporting structures
Page 20 of 25
1. Trusses and supporting structures shall be designed to carry their dead load, material
loads (including material loads due to plugged chutes filled to capacity), walkway live
load, and 34 kg/0.3m (75 lb/ft) load for electrical raceways and lighting.
2. If applicable, piping and/or cable tray loads shall be added.
3. Maximum belt tensions created by starting or under stalling conditions shall be used
in design of support members.
c. Vertical deflections of trusses under gravity loads, except dead loads and lateral deflections
under wind loads, shall not exceed 1/600th of span.
d. In addition to primary forces, design of truss members shall take into account secondary
forces due to eccentric connections.
e. For load combination purposes, conveyor loads shall be treated as equipment load and
equipment operation load.
8.3. Design basis
8.3.1. General
a. Steel structures shall be designed by working stress method.
b. Stability of structure shall be checked for all load conditions.
c. In no case shall safety factor be less than the following:
Load Safety factor
Overturning 1.50
Sliding 1.50
Uplift 1.50
8.3.2. Steel structures

a. Steel structures shall be designed in accordance with AISC 101.
b. The following loading combinations shall be considered:
1. DL + DLe + LL + LLo + SL.
2. DL + DLe + LL + LLo + WL.
3. DL + DLe + LL + LLo + 0.25 SL + EL.
4. DL + DLe + LL + LLo + 0.5 WL.
5. DL + DLe + LL + 0.5 SL + LLo + EL .
6. DL + WL.
7. DL + DLe + CL.
c. For loading combinations 2, 3, 4, 5, and 6., allowable stress may be increased by 33% in
accordance with ICC.
8.3.3. Fatigue stress

For welded connections of all major structural elements, including conveyor trusses, effects of
fatigue stresses shall be considered in accordance with AISC 101.
8.4. Materials
a. Structural steel shapes and plates shall comply with ASTM A36.
Page 21 of 25
b. Bolts for members shall comply with ASTM A235 “bearing type”, with threads in any
shear plane, except “friction type” bolts shall be used if dynamic loading or stress reversal
occurs.
c. ASTM A307 bolts may be used for secondary framing, such as walkways, stairs, and
ladders.
d. Welding materials shall comply with AWS A5.17, AWS A5.18, and AWS A5.1.
9. Control devices
9.1. Emergency stop switches

a. Conveyor and belt feeders shall have manually reset type emergency stopping devices with
mechanical flag to indicate normal or tripped position.
b. Protection shall extend for full accessible length of conveyor up to guards on terminal
pulleys.
c. Pullcords shall be plastic covered 4 mm (5/32 in) stainless steel aircraft cable supported on
3 m (10 ft) maximum spacing.
d. Pullcords shall not be solidly anchored but be attached to safety switches at both ends.
e. Allowable spacing between switches shall be 30 m (200 ft) maximum.
f. Installation shall be made such that operators can stop equipment from any position on
walkway along equipment.
9.2. Low speed switch

a. Low speed switch shall be installed on suitable nonpowered pulley on each conveyor and
belt feeder at position shown on data sheets.
b. Malfunctions that cause belt to slow down shall be detected by low speed switch.
c. Speed at which switch operates shall be adjustable.
d. Contacts shall be double pole, double throw.
9.3. Side travel switches

a. Four side travel switches shall be installed on each belt conveyor, two at drive pulley and
two at tail pulley.
b. Switches shall be “whisker” or “wobble” type.
c. Two sets of independently adjustable double pole, double throw contacts shall be provided,
one set for warning and one set for shutdown.
9.4. Plugged chute detectors

a. Vendor shall determine location and provide for mounting of plugged chute switches.
b. Nuclear level switches will be provided and installed by BP.
10. Other requirements
10.1. Calculations
a. Design calculations shall be submitted on all engineered equipment.
b. If computer is used by Vendor, input and output data shall be submitted, as well as basis of
computations.
Page 22 of 25
10.2. Belting
a. Belting shall be specified by Vendor but provided by others.
b. Unless specified otherwise, belts shall have vulcanized splices.
c. Vulcanized spliced belts shall have multiple plys.
d. Maximum standardization shall be required, with one belt specification per belt width.
e. Unless specified otherwise, the following belts shall be used for applicable service:
Service Belt type
Green coke Standard sand and gravel belt
Calcined coke less than 121°C (250°F) Heat and oil resistant
Calcined coke greater than 121°C (250°F) Heat resistant
10.3. Welding
Welding shall comply with AWS D1.1.
10.4. Diverter gates

a. Diverter gates shall be designed for minimum of 2 years of uninterruptible service without
maintenance.
b. Sides of gate shall be lined with abrasion resistant plates.
c. Shaft shall be bolted to gate and shall be supported by self aligning flange mounted
bearings installed outside of diverter chute.
d. Gate shall be actuated by shaft mounted right angle gear drive electric motor or double
acting pneumatic cylinder.
e. Adjustable limit switches shall be provided to detect gate position.
11. Assembly
a. Critical dimensions shall be verified and checked for fit and match marked prior to
shipping.
b. Items shall be shop assembled to maximum practical extent for ease of field erection.
c. The following procedure summarizes the extent of shop assembly:
1. Conveyor complete assemblies shall be shipped in 12 m to 18 m (40 to 60 ft) section
lengths.
2. Walkthrough trusses shall be shipped completely assembled.
3. Standard trusses shall be shipped in two sections completely assembled. One section
shall be box truss, and other section shall be walkways, handrail, and outriggers.
4. Channel frame conveyors shall be shipped completely assembled, except for legs.
5. Covers shall be completely assembled on conveyors.
6. Bend pulleys for gravity takeups shall be completely assembled on conveyor. Gravity
takeup guides, takeup pulley, and takeup box shall be shipped as complete unit.
7. Drive units shall be strapped to conveyor frame at drive end of conveyor.
8. Bents shall be shipped knocked down.
9. Field splices and bolts shall be shipped loose with conveyors that require field splices.
10. Belt feeders shall be shipped completely assembled.
Page 23 of 25
11. Trippers shall be shipped completely assembled.

12. Chutes shall be shipped with liners installed.
12. Tests and inspections
a. Conveyor components shall be dimensionally shop checked and inspected to ensure proper
fit at field installation.
b. Conveyor assembled sections shall be shop fit with adjacent sections prior to shipment.
This shall be a BP inspection hold point.
c. Critical dimensions shall be verified and all parts checked for defects in material and
workmanship.
d. Field test shall be conducted on completion of system installation, under supervision of
Vendor representative, to determine that operational performance is in compliance with
specifications.
e. Conveyor field test shall consist of no load and full load alignment run of 4 hours each,
without stoppages due to equipment malfunctions.
13. Installation checklist
The following checklist points shall be witnessed by BP project engineer:

Installation checklist was developed to ensure proper installation of critical fittings.
a. Maintain conveyor troughing and return idlers to within 2 mm (0.10 in) variation about
true centreline of conveyor from head to tail pulleys.
b. Verify loading trough centreline position as being within 6 mm (0.25 in) of impact idler
centreline.
c. Verify that skirtboard liner is positioned 6 mm to 9 mm (1/4 in to 3/8 in) above conveyor
belt at all loading points.
d. Check that skirtboard liner has no internal steps or spaces to “catch” material.
e. Verify that loading trough tail end rubber seal is positioned 6 mm (1/4 in) off of belt to
prevent material buildup or spillage.
f. Maintenance access shall not be blocked by conduit.
14. Spare parts
a. Listing of spare parts shall be provided.

b. Current prices for equipment provided shall be indicated.
c. List shall designate those items recommended to have on hand during startup and those
items recommended for 1 year of operation.
d. Vendor shall comply with project specifications when making equipment quotation and
after receipt of equipment purchase order.
e. Operating and maintenance manuals for machinery under purchase order shall be provided.
Manuals shall contain “exploded view” illustrations as required for facilitating
maintenance.
Page 24 of 25
15. Material safety data sheets (MSDS)
a. Equipment or materials that contain or are coated with any regulated substances, such as
the following, shall be prominently tagged at openings to indicate nature of contents and
precautions for shipping, storage, and handling:
1. Insulating oils.
2. Corrosion inhibitors.
3. Antifreeze solutions.
4. Desiccants.
5. Chemical substances.
6. Hydrocarbon substances.
b. Regulated substances shall have a Material Safety Data Sheet (MSDS).
c. MSDSs shall fully comply with regulations for MSDS preparation specified by entity that
has jurisdiction and shall include a statement that the substance is considered hazardous by
regulation.
d. If any substance is exempt from regulation, a statement to that effect shall be included.
e. Before shipment, MSDSs shall be forwarded to receiving facility.
f. At shipment, MSDSs in protective envelopes shall be affixed to the outside of the
shipment.
Page 25 of 25

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Document No.

Guidance on Industry Standard for

5.3. Deck plate.................................................................................................................. 16

American Institute of Steel Construction (AISC)

American National Standards Institute (ANSI)

American National Standards Institute (ANSI) / American Gear Manufacturers

American National Standards Institute (ANSI) / National Fluid Power Association

American Society for Testing and Materials (ASTM)

American Welding Society (AWS)

BP Engineering Technical Practices (ETPs)

Conveyor Equipment Manufacturers Association (CEMA)

International Code Council (ICC)

a. Equipment shall be suitable for outdoor or indoor installation as specified.

4.2.2. Troughing idlers

4.2.3. Training idlers

4.2.4. Return idlers

4.2.5. Impact idlers

4.2.6. Transition idlers

4.2.7. Picking idler

4.2.8. Belt scale idlers

4.2.9. Idler spacing

4.3.3. Assemblies and shipping

4.4. Shafting (pulleys)

4.4.1. Turned down shaft ends

4.4.2. Shear stress

4.4.3. Bending stress

4.4.4. Service factor

4.4.6. Shaft diameters

4.5. Bearings and housings

4.6. Conveyor drives

4.8. Backstops or holdbacks

4.10. Access to drives and removability

4.12. Wind covers and windboards

4.14.1. Screw takeups

4.14.2. Vertical gravity takeups

4.14.3. Tail pulley takeups

4.14.4. Counterweight safety cages

4.14.5. Rope and sheaves

4.15.2. Return run plows

5.2. Belt feeder frame

5.3. Deck plate

5.4. Belt feeder drives

6. Belt conveyor trippers

6.1. Operating conditions

6.2. Design and construction

7. Chutes and platework

7.3. Chute valley angles

7.4. Abrasion resistant liners

7.5. Conveyor skirtboards and skirts

1. Designed to allow smooth flow of material.

7.6. Deck plates and protection at road crossings

7.7. Drip pans and covers

7.7.2. Flanged drain connections

7.7.3. Drip pan covers

8. Structural steel for conveyors

8.1. Design loads

g. Live load reduction shall comply with ICC.

8.2. Design considerations