MD 101 Smem Eg Me SPC 0005

Ma’aden Engineering Manual Rev.
Date: 26 Jul 2011

Specification Rev: C01
Table of Contents
1. Introduction ............................................................................................................................................ 4
1.1 Scope ............................................................................................................................................. 4
1.2 Purpose .......................................................................................................................................... 4
2. Key Terms and Definitions ...................................................................................................................... 4
3. referenced Documents ............................................................................................................................ 5
3.1 Statutory Regulations ...................................................................................................................... 5
3.2 Industry Codes and Standards ......................................................................................................... 5
3.2.1 International Codes and Standards ...................................................................................... 5
3.2.2 Ma’aden Standards .............................................................................................................. 7
3.3 Site Data ......................................................................................................................................... 7
4. Design Requirements .............................................................................................................................. 7
4.1 General Requirements .................................................................................................................... 7
4.1.1 Design Criteria .................................................................................................................... 7
4.1.2 Operating Requirements ..................................................................................................... 8
4.2 Conveyor Drives ............................................................................................................................. 8
4.2.1 General ............................................................................................................................... 8
4.2.2 Motors ............................................................................................................................... 9
4.2.3 Gearboxes .......................................................................................................................... 9
4.2.4 Couplings ......................................................................................................................... 10
4.2.5 Baseplates ......................................................................................................................... 10
4.3 Take–Ups ..................................................................................................................................... 11
4.3.1 Manual Take-Ups .............................................................................................................. 11
4.3.2 Automatic Take-Ups.......................................................................................................... 11
4.4 Conveyor Belting .......................................................................................................................... 11
4.4.1 General ............................................................................................................................. 11
4.4.2 Cover Rubber .................................................................................................................... 12
4.4.3 Splicing ............................................................................................................................. 12
4.4.4 Belt Stretch ....................................................................................................................... 12
4.4.5 Belt Width ........................................................................................................................ 13
4.4.6 Belt Length ........................................................................................................................ 13
4.5 Pulleys .......................................................................................................................................... 13
4.5.1 General ............................................................................................................................. 13
4.5.2 Shells and End Discs ......................................................................................................... 13
4.5.3 Shafts ............................................................................................................................. 14
4.5.4 Bearings ............................................................................................................................ 14
4.5.5 Lagging ............................................................................................................................. 15
4.5.6 Identification ..................................................................................................................... 15
4.5.7 Painting and Protective Coatings ....................................................................................... 15
4.6 Idlers ............................................................................................................................................ 15
4.6.1 General ............................................................................................................................. 15
4.6.2 Carrying Idlers .................................................................................................................. 17
4.6.3 Return Idlers ..................................................................................................................... 19
4.7 Belt Magnets ................................................................................................................................. 20
4.7.1 General ............................................................................................................................. 20
4.7.2 Magnet Requirements ....................................................................................................... 20
4.8 Belt Cleaning ................................................................................................................................ 20
4.9 Chutes .......................................................................................................................................... 20
4.9.1 General ............................................................................................................................. 20
PROPRIETARY & Materials Handling – Belt Conveyor Systems

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CONFIDENTIAL Doc No: MD-101-SMEM-EG-ME-SPC-0005
Ma’aden Engineering Manual Rev. Date: 26 Jul 2011
4.9.2 Guarding .......................................................................................................................... 21

4.9.3 Materials ........................................................................................................................... 21
4.9.4 Liners ............................................................................................................................. 21
4.9.5 Skirts ............................................................................................................................. 22
4.9.6 Fasteners ........................................................................................................................... 23
4.9.7 Painting and Protective Coatings ....................................................................................... 23
5. Manufacturing/Installation Requirements ............................................................................................. 24
5.1 General ........................................................................................................................................ 24
5.1.1 Welding ............................................................................................................................ 24
5.1.2 Bearings ............................................................................................................................ 24
5.2 Conveyor Drives ........................................................................................................................... 24
5.2.1 Gearboxes ........................................................................................................................ 24
5.2.2 Couplings ......................................................................................................................... 24
5.3 Take-Ups ...................................................................................................................................... 24
5.5 Pulleys .......................................................................................................................................... 25
5.5.1 Manufacture ...................................................................................................................... 25
5.5.2 Assembly .......................................................................................................................... 26
5.5.3 Shaft ............................................................................................................................. 26
5.6 Idlers ............................................................................................................................................ 27
5.7 Belt Magnets ................................................................................................................................. 27
5.8 Belt Cleaning ................................................................................................................................ 27
5.9 Chutes .......................................................................................................................................... 27
6. Quality .................................................................................................................................................. 27
6.1 General ........................................................................................................................................ 27
6.1.1 Shop Assembly and Testing ............................................................................................... 28
6.1.2 Site Testing ....................................................................................................................... 28
6.1.3 Maintenance ..................................................................................................................... 28
6.3 Pulleys .......................................................................................................................................... 29
6.4 Idlers ............................................................................................................................................ 29
6.5 Chute Liners ................................................................................................................................. 29
7. Transport, Packaging, Handling and Shipping ....................................................................................... 30
7.1 Belt Handling ............................................................................................................................... 30
7.2 Pulleys .......................................................................................................................................... 30

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1. INTRODUCTION
1.1 Scope
This Specification covers the minimum requirements for the design, fabrication, testing and
supply of components used in belt conveyor materials handling systems on Ma’aden projects
in the Kingdom of Saudi Arabia.
This document is intended to be used in conjunction with the documents listed herein.
1.2 Purpose
The purpose of this Specification is to:
• Set the minimum engineering standard for materials handling systems
• Standardize components and minimize spare parts requirements.
2. KEY TERMS AND DEFINITIONS

ASME American Society of Mechanical Engineers
ANSI American National Standards Institute
ASTM American Society for Testing and Materials
AWS American Welding Society
BS British Standard
DOL Direct on Line Motor
EN European Standard
HV High Voltage (V > 1000 VAC)
ISO International Standards Organization
ITP Inspection and Test Plan
LV Low Voltage (V ≤1000 VAC)
MDR Manufacturer’s Data Report
NDT Non Destructive Testing
NPT National Pipe Thread
TIR Total Indicated Run Out
Approval Formal confirmation by an authorized person that activities laid

down in a document or a service/product is acceptable
Contractor An entity, engaged or approved by the Employer, entrusted with a

contract to perform work or cause work to be performed

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Employer Saudi Arabian Mining Company (Ma’aden) and its authorized

representatives and respective affiliates
Vendor An intermediary who supplies manufactured equipment, or

manufactures the required plant and equipment
3. REFERENCED DOCUMENTS
This specification requires compliance with the provisions of the latest revision of the
relevant standards and codes of the following authorities and technical organizations, as
applicable, and specifications which shall be considered to form part of this specification,
where applicable.
3.1 Statutory Regulations
All work performed and materials furnished shall comply with the applicable statutory
regulations, codes and other requirements of the Kingdom of Saudi Arabia (including but not
limited to directives of the High Commission for Industrial Security, Royal Commission
regulations applicable to the Site, regulations of the Presidency of Meteorology and
Environment, Saudi Building Code and other applicable codes and regulations).
The Contractor shall ensure that he is fully aware and informed of all Government laws, local
ordinances, regulations and all orders and decrees of bodies or tribunals having any
jurisdiction or authority over the Project and/or Site, which in any manner affect the Project
and those engaged or employed on the Project, or which in any way affect the conduct of
the Work. The Supplier shall at all times observe and comply with all such Government
and/or Ministry laws, bylaws, ordinances, codes, regulations, orders and decrees.
3.2 Industry Codes and Standards
3.2.1 International Codes and Standards
ANSI/AGMA 6010-F97 Spur, Helical, Herringbone and Bevel Enclosed Drives
ASME B16.5 Steel Pipe Flanges & Flanged Fittings
ASME Section V Boiler and Pressure Vessel Code : Section V : Non Destructive
Examination
ASME Section VIII Boiler and Pressure Vessel Code : Section VIII : Design and
Fabrication of Pressure Vessels
ASTM A6/A6M Rolled Structural Steel Bars, Plates Shapes and Sheet Piling
ASTM A484/A484M Standard Specification for General Requirements for Stainless

Steel Bars, Billets, and Forgings
ASTM A609/609M Standard Practice for Castings, Carbon, Low-Alloy, and

Martensitic Stainless Steel, Ultrasonic Examination Thereof
ASTM E10 Test Method for Brinell Hardness of Metallic Materials

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ASTM E45 Standard Test Methods for Determining the Inclusion Content
of Steel
ASTM E165 Standard Practice for Liquid Penetrant Examination for General
Industry
ASTM E709 Standard Guide for Magnetic Particle Testing
AWS D1.1 American Welding Society – Structural Steel Welding Code
BS 1134 Assessment of surface texture. Guidance and general

information.
BS EN 1561 Founding. Grey Cast Irons.
BS ISO 281 Rolling bearings. Dynamic load ratings and rating life.
BS ISO 355 Rolling bearings. Tapered roller bearings. Boundary

dimensions and Series Designations.
BS ISO 19960 Cast steels and alloys with special physical properties series
designations
CEMA Belt Conveyors for Bulk Materials
DIN 22102-1 Conveyor belts with textile plies for bulk goods – Part 1:
Dimensions, Specification, marking
DIN 22102-2 Conveyor belts with textile plies for bulk goods – Part 2:
Testing
EN 10204 Metallic Products. Types Of Inspection Documents
ISO 281 Rolling Bearings – Dynamic Load Ratings and Rating Life
ISO 282 Conveyor belts – Sampling
ISO 286-1 ISO system of limits and fits – Part I: Bases of tolerances,
deviations and fits
ISO 286-2 ISO system of limits and fits – Part II: Tables of standard
tolerance grades and limit deviations for holes and shafts
ISO 505 Conveyor belts – Method for determination of the tear

propagation resistance of textile conveyor belts
ISO 583 Conveyor belts with a textile carcass – Total belt thickness and
thickness of constitutive elements – Test methods
ISO 898-1 Mechanical properties of fasteners made of carbon steel and

alloy steel – Part 1: Bolts, screws and studs with specified
property classes – Coarse thread and fine pitch thread
ISO 1940 Mechanical Vibration – Balance Requirements

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ISO 3912 Specification for metric keys and keyways. Woodruff keys and
keyways.
ISO 4649 Rubber, vulcanized or thermoplastic – Determination of

abrasion resistance using a rotating cylindrical drum device
ISO 14120 Safety of machinery – Guards – General requirements for the

design and construction of fixed and movable guards.
3.2.2 Ma’aden Standards
MD-101-SMEM-EG-CV-SPC-0002 Anchor Bolts
MD-101-SMEM-EG-ME-SPC-0007 Protective Coatings
MD-101-SMEM-EG-ME-SPC-0009 Welding
MD-101-SMEM-EG-EL-SPC-0004 Electric Motors
MD-101-SMEM-EG-ME-CRT-0002 Design Criteria – Mechanical Equipment
MD-101-SMEM-EG-ME-SPC-0002 Mechanical Equipment Installation
MD-101-SMEM-EG-ST-CRT-0001 Structural Design Criteria for Process Buildings and

Structures
MD-101-SMPM-PM-QA-PEI-0001 Contractor Quality Requirements
3.3 Site Data

All materials, equipment and work methods shall be suitable for the Site conditions as
defined in the applicable Site Data Specification.
4. DESIGN REQUIREMENTS
4.1 General Requirements
All equipment shall be designed in accordance with Ma’aden Standard Specification –
MD-101-SMEM-EG-ME-CRT-0002 – Design Criteria – Mechanical Equipment to provide
continuous, long-term service under prevailing ambient and environmental conditions as
indicated in Ma’aden Standard Specification – MD-101-SMEM-EG-GE-SPC-0001 – Site Data.
The Employer desires to standardize the design of all possible items of equipment across the
plant. Where practicable, identical components shall be used to allow interchange of parts,
minimize spare part requirements and to aid standardization of service and repairs.
Conveyors and associated equipment shall be designed for continuous operation with up to
10 starts per hour.
4.1.1 Design Criteria
Detailed Specifications and Data Sheets for item of equipment shall incorporate the
requirements of this document and recognized engineering practice. Only proven
equipment shall be selected.

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Noise levels under normal operation shall not exceed the sound pressure levels stated in
Ma’aden Standard Specification – MD-101-SMEM-EG-ME-CRT-0002 – Design Criteria –
Mechanical Equipment.
All exposed moving parts shall be guarded to ISO 14120. Guards shall be modular panels
designed to allow manual installation and removal by a single person with minimum use of
hand tools, wherever possible.
Where practical all assemblies and components shall be provided with suitable lifting lugs or
eyebolts to allow for easy off-loading, site installation and maintenance purposes. Lifting
lugs shall be stamped with their rated capacity. The total mass of each item of equipment
shall also be clearly marked.
All equipment supplied shall facilitate easy inspection, cleaning, lubrication, and
maintenance and prevent undue stresses resulting from expansion due to temperature
changes.
4.1.2 Operating Requirements
The Vendor’s selection shall suit the full range of operating conditions and process
parameters stated in this Specification and equipment pump Data Sheets for each
application.
4.2 Conveyor Drives
4.2.1 General
Foot mounted conveyor drives shall be supplied with the following items fully assembled,
fitted and aligned:
• Motor
• High Speed Coupling
• Gearbox (with integral backstop)
• Low Speed Coupling
• Baseplate.
The mating half of the low speed coupling shall be supplied to the pulley Vendor for fitting
onto the pulley.
Shaft mounted conveyor drives shall be supplied with the following items fully assembled,
fitted and aligned:
• Motor
• Close coupling of motor to gearbox
• Shaft mounted helical/bevel gearbox with torque arm
• An integral high speed backstop
• Dual shafts with a hollow output shaft.

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4.2.2 Motors
Electrical motors shall be foot mounted and supplied in accordance with Ma’aden Standard
Specification – MD-101-SMEM-EG-EL-SPC-0004 – Electric Motors and shall be supplied as:
• 415 V LV motors for conveyor systems up to a maximum power rating of 200 kW, and
4.16 kV HV motors for sizes greater than 200 kW unless otherwise noted on conveyor
drive Data Sheets
• 415 V LV motors for conveyor systems with variable speed drives up to a maximum
power rating of 315 kW.
Motor sizing shall consider drive losses to cover gearbox efficiency ratings and variable
speed drive losses where applicable.
Where motors are nominated as being variable speed on drive Data Sheets, motor selection
shall be based on:
• Providing a non overloading design over the motors output torque range coinciding with
the required conveyor speed and absorbed power at normal, maximum and minimum
duty conditions as specified on the Data Sheets)
• Allowance for motor thermal derating shall be taken into account over these reduced
speeds.
4.2.3 Gearboxes
4.2.3.1 General
Gearbox design and selection shall be in accordance with the requirements of
AGMA 6010-F97. In addition gearboxes shall comply with the following:
• Designed for an operating life of 100,000 hours
• Have thermal ratings calculated on full sun exposure and 3 m/s wind speed, if located
outdoors, or no sun exposure and 1.4 m/s wind speed if located indoors
• Be rated such that supplementary cooling is not required under any operating conditions
• Have service factors on demand power of 1.5 for durability and 2 for strength
• Have true speed reduction ratios of ±6% of the corresponding nominal ratios
• Be symmetrical so that handing, shaft rotation, reducer position etc. can be modified.
4.2.3.2 Housing
All housings shall be designed to withstand the combined effects of the radial, axial and
overhung loads normally applicable to conveyor drives having the maximum permissible
misalignment.
The housings shall be of rigid construction, totally enclosed, dust-proof, splash-proof,

horizontally or vertically split and equipped with inspection covers, drain and filler plugs, oil
seals and gaskets, breathers, level indicators and lifting lugs.
Housings shall be fabricated from either high grade close-grained cast iron to BS EN 1561 or
fabricated steel to BS ISO 19960. Alternative equivalent or superior grades may be used
upon Approval by the Employer.

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4.2.3.3 Lubrication and Seals

Gearboxes shall be fitted with lip and grease purged taconite seals. The gearboxes shall be
oil lubricated and enclosed complete with an air breather.
4.2.3.4 Bearings
Rolling element bearings shall have a minimum L10 life of 50,000 hours as calculated in
accordance with the requirements of ISO 281.
The bearings are to be manufactured in accordance with BS ISO 355 and shall be from a
reputable manufacturer.
4.2.3.5 Holdbacks
Holdbacks shall be located on the first reduction shaft extension external to the gearbox.
Holdbacks shall have a nominal torque rating of at least 110% of the specified flooded belt
run back torque and at least 110% of maximum motor stalled torque.
4.2.3.6 Shafts
Shafts shall be mounted in anti-friction bearings, which are located in precision machined
bearing housings. Limits and fits to be in accordance with ISO 286-1 and ISO 286-2.
4.2.4 Couplings
Coupling design and selection shall be in accordance with the following requirements:
• Couplings shall be selected with a service factor as recommended by the motor
manufacturer (except that the service factor shall not be less than 1.5) applied to the
drive motor nameplate continuous rated power
• All couplings shall be complete with keyways and tapered hubs with split compression
type bushings
• Controlled torque couplings shall be considered where applicable, to prevent damage to
the motor in case of equipment stall
• Coupling guards shall be fitted in accordance with the requirements of ISO 14120.
4.2.4.1 Fluid Couplings
Fluid couplings may be used where softening or limiting of starting or slowing torques is
required. Fluid couplings shall be of the extended delay type and shall be capable of ten
equally spaced start-ups per hour at maximum design load.
4.2.5 Baseplates
All baseplates shall be fabricated from ASTM A6/A6M steel or equivalent and shall be
designed to allow handing, shaft rotation and base plate position relative to conveyor to be
modified.
Baseplates shall be designed as self draining.
Coating of baseplates shall be as per equipment data sheet.
Baseplate anchor bolts shall conform with Ma’aden Standard Specification

MD-101-SMEM-EG-CV-SPC-0002.

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4.3 Take–Ups
All conveyor systems shall include a take up device to maintain belt tension and to facilitate
belt installation and repair. Take-up design shall be in accordance with CEMA
recommendations.
4.3.1 Manual Take-Ups
Take-ups on conveyors with belt widths less than 1200 mm and less than 50 m long shall be
screw type unless advised otherwise. The take-up length shall provide for the longest
foreseeable belt elongation and for the requirements of belt splicing.
Screw take-ups shall utilize hydraulic cylinders to achieve the belt tension with screw and
nut system used to hold the take-up pulley after tensioning. The hydraulic system shall
include load cells or pressure gauges arranged to indicate and apply even take-up force at
both sides of the take-up pulley.
Fixed take-up systems may be incorporated on conveyors longer than 50 m only when
Approved by the Employer.
Where the fixed take-up force is significantly large for conventional hydraulic cylinders to be
adapted, then a hydraulic winch with speed control (including indicated force) and a failsafe
locking system (i.e. can hold tension when winch is not operating) shall be used.
4.3.2 Automatic Take-Ups
All other conveyors shall be gravity take-up type unless otherwise directed by the Contractor.
When layout permits, festoon type gravity take-ups are preferred otherwise tail trolley take-
ups may be utilized.
The gravity take-up mass shall be selected to satisfy the most stringent requirement for slack
side tension at the drive pulley. If the take-up is remote from the drive then the following
factors shall be included in the evaluation of take-up mass.
• Difference in elevation between the take-up and the drive
• Frictional drag of belt, idlers and pulleys between the take-up and the drive
• Forces to accelerate belt, idlers and pulleys between the take-up and the drive.
If the take-up mass is connected to a take-up pulley via ropes and sheaves, due consideration
shall be given to the sheave friction.
The minimum total take-up travel of gravity systems shall be:

• Steel Cord Belt = 0.25% x Conveyor length + 1 splice length
• Fabric Belt = 2.0% x Conveyor length + 1 splice length.
The take-up travel of other systems shall be Approved by the Contractor.

4.4 Conveyor Belting
4.4.1 General
All conveyor belting shall be of polyester/nylon construction and shall be manufactured in
accordance with the requirements of ISO 583 and DIN 22102-1.

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The belt design shall incorporate both the steady state running conditions, as well as
momentary conditions of overload, such as starting and braking.
Selection of conveyor belt carcasses shall be suitable for site conditions and be strictly in
accordance with the belt manufacturer’s recommendations as regards:
• The material and tensions loads
• Belt speed
• Material impact energy
• Pulley size and configuration, including the use of snub pulleys imposing reverse
bending stresses on the splices
• Idler configuration
• Horizontal curves
• Vertical curves
• Belt turnovers.
Cover thicknesses shall be selected strictly in accordance with the belt manufacturer’s
recommendations as regards:
• Suitability for use with ceramic lagged drive pulleys
• Material abrasiveness, chemical properties and conveyor cycle time
• Material density, lump size and drop height at conveyor loading points.
4.4.2 Cover Rubber
The belt cover thickness shall be as stated on Data Sheets. The manufacturer shall confirm
that this is suitable for the operation intended.
The proposed top cover rubber compound shall be suited to the operating and momentary
conditions as stated on Data Sheets. The top cover will be subject to wear due to loading on
both the top and bottom strands of the conveyor.
The proposed bottom cover compound shall be selected to minimize power consumption.
The cover compound shall include compounds for protection against ultra-violet radiation.
4.4.3 Splicing
Synthetic carcass belts shall be suitable for:
• Hot and cold vulcanizing
• Mechanical fasteners (carcass shall not be weakened by more than 10% when
mechanical fasteners are used).
Belt rating shall be as stated on Data Sheets. The Service Factor (SF) used in belt rating
selection shall be 5.5. Momentary starting conditions are designed to maintain a belt rating
SF of 4.0. However, the belt shall be capable of withstanding momentary overloads of 150%
over belt rating, or a reduction in SF to 3.7.
4.4.4 Belt Stretch
The permanent stretch shall be less than 2.5% of the conveyor terminal pulley centers.

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4.4.5 Belt Width

The vendor shall provide full belt width as manufactured in one fabricating press. The
slitting of fabricated belting to a lesser stock width or making of two belts in one belt press is
not acceptable.
Consideration for belt edge molding shall be made for chemically reactive materials.
4.4.6 Belt Length
The purchased length may vary ± 2% from the specified value. Therefore, the quoted cost
per unit length shall be the controlling factor. The total number of rolls required to deliver a
specific length shall be specified.
4.5 Pulleys
4.5.1 General
Pulleys shall be designed such that stress during normal operation is below the fatigue
endurance limit of the material selected.
All pulley components shall be designed to safely withstand the maximum force that can be
imposed during acceleration and deceleration (braking). In addition, all drive pulleys shall
be designed to safely withstand the full stalled torque of the driving motor and the belt
tension arising from this torque.
Pulley widths shall be:

• Belt width + 100 mm for belt widths 1000 mm or less
• Belt width + 150 mm for belt widths greater than 1000 mm.
Head and tail pulleys used with fabric belt shall be crowned. The centre third of the pulley
shall be flat while the end thirds shall be crowned. The diameter at the crown shall be 6 mm
greater than the diameter at the ends and the end diameter shall be the nominated shell
diameter. Crowning shall be machined in the shell. Pulleys for use with steel cord belting
shall not be crowned.
4.5.2 Shells and End Discs
The preferred material for shells and end discs is structural grade plate in accordance with
ASTM A6/A6M. End disc hubs shall be designed for use with locking elements. Pulley end
discs shall be integral with the hubs.
Maximum stresses (including combined) in the end discs shall not exceed 52 MPa.
Intermediate discs are not acceptable.
Shell diameters shall be selected strictly in accordance with the belt manufacturer’s
recommendations for minimum pulley diameters with regard to the belt carcass selected and
design tensions in the belt.
The thickness of end-discs where it is welded to the shell shall not exceed 1.2 times the shell
thickness and shall be designed to prevent end disc forces being transmitted to the shell.
Crowning (where requested) shall be 1 in 100. Varying the thickness of the lagging for
crowning shall not be allowed.
The Vendor shall indicate at what shell thickness the pulley should be replaced.

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Either rolled plates or steel forgings may be used for the hubs, provided that the carbon
content is under 0.20% by mass.
4.5.3 Shafts
The Vendor shall use standard shaft diameters designed with reference to ISO 286-2 for
determination of fitting tolerances and the corresponding stress raising factors for locking
mechanisms, bearings and coupling attachments. Shaft forces, moments and torsion shall be
calculated using the maximum force that can be imposed during acceleration and braking.
Pulleys shall be attached to their shafts using twin taper locking elements. Shafts shall be
designed such that the maximum deflection at the locking element under normal operating
tensions does not exceed that recommended by the manufacturer of the locking element.
The maximum slope resulting from deflection at the locking elements shall not exceed
0.0015 radians. Calculated by considering the shaft as a beam, simply supported at the
bearing journal centers.
For drive pulleys, the drive side locking element shall be capable of transmitting at least
200% of the motor pullout torque, multiplied by the overall drive reduction ratio. The non-
drive side locking element shall be of the same size and type as the drive side locking
element.
Shafts shall be machined from a single billet and shall be fully killed. Shafts of greater than
120 mm diameter shall be normalized. Keyways in pulley shafts are not generally
acceptable except where slow speed holdbacks are fitted to an extended shaft. In this case,
keys and keyways shall be in accordance with ISO 3912.
The shaft design shall allow for a maximum of 20% reduction in diameter for each step.
Radii for step-down shafts shall be at least equal to the difference between the diameters.
4.5.4 Bearings
All bearings shall be taper bore spherical roller bearings.
Each pulley shall have one fixed and one floating bearing. Bearings and bearing housings
shall be identical on both ends of each shaft. Each housing shall be clearly marked with the
symbols, L (for located) and F (for floating) hard stamped on the end covers. Drive pulleys
driven from one end only shall have the located bearing assembly on the driven end of the
pulley shaft.
Sealing blanks shall be installed on the outboard ends of non-drive bearing housings. All
bearing end covers shall:
• Fit grease-tight and dirt-tight in the housing throat groove
• Be suitable for shafts which project 10 mm beyond the end of the adapter sleeve
• Be made of steel or cast iron
• Be supplied by a reputable manufacturer.
Bearings shall be installed according to manufacturer’s instructions to achieve the designated

bearing locations on the pulley shaft. Bearing internal clearance shall be recorded for each
bearing.

Page 14 of 30
Bearings on shafts of less than 150 mm shall be mounted using taper sleeves. Bearings on
shafts of diameter 150 mm or greater shall be hydraulically demountable.
Bearings shall be fitted with lip & taconite seals and have a minimum L10 life of
60,000 hours, calculated in accordance with ISO 281. Housing types shall be as follows:
Bearing housing type SN 500 series <40 mm diameter shaft, 2 bolt mounting.
Bearing housing type SSN 500 series >40 to ≤140 mm shafts, 2 bolt mounting.
Bearing housing type SD 3100 series ≥150 mm shafts, 4 bolt mounting.
The deflection criteria shall be selected to protect the bearing seals and locking elements on
the pulley and to prevent undue transmittal of force couples to the supporting structure.
Deflection criteria shall be based on the most stringent of the following:
• Deflection shall not to be in excess of L/2500 (L = bearing centers)
• The deflection angle shall not be more than four minutes at the pulley locking element
or not more than five minutes at the shaft end
• Manufacturers’ requirements.
4.5.5 Lagging
Pulley lagging shall be as nominated on Equipment Data Sheets.
Lagging shall have a Shore Hardness of 50 – 60 for non-drive pulleys and 60 – 70 for drive
pulleys.
All lagging on drive pulley shall be diamond pattern grooved.

4.5.6 Identification
All pulleys shall be provided with a nameplate that lists the following information:
• Pulley designation
• Contract/Purchase order number
• Date of manufacture
• Locking element torque.
4.5.7 Painting and Protective Coatings
Surface preparation and painting shall be in accordance with Ma’aden Standard
Specification, MD-101-SMEM-EG-ME-SPC-0007, Protective Coating.
4.6 Idlers
4.6.1 General
4.6.1.1 Construction
All idlers shall be of heavy-duty construction, manufactured from electric resistance welded
tubing.
Idler shells and end bearing housings shall have a minimum wall thickness of 4.0 mm. End
bearing housings shall be fully welded to idler shell. The vendor shall nominate, complete
with calculations, actual thickness required.

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The roll diameter of all carry idlers on new installations with 1800 mm or wider belt widths
shall be 178 mm diameter. The roll diameter of all other idlers shall be 152 mm unless
otherwise advised by the Contractor. This diameter shall be inclusive of any rubber discs.
Frames shall be designed for flooded conveyor load with allowance made for torsion due to
seized rolls. Where required, trough frames shall be fitted with a diagonal brace between
the outer support arm and the cross member.
The tolerance for the overall roll diameter shall be + 0.5 mm and – 0.0 mm.
Roller ends shall have a corner radius of 3 mm minimum over 90°.
The angular deflection shall not exceed 0.00175 radian at the bearings and seals, under
worst case load conditions.
The shaft size and type shall be at least to the associated components manufacturer's
requirements in particular to deflections at bearings and seals to service the duty specified.
The idler shall be of a construction to withstand an environment of high dust concentration

and high pressure water wash down.
4.6.1.2 Bearings
Unless advised otherwise all idlers shall be fitted with deep grooved ball bearings. The
bearings shall have a minimum L10 life of 75,000 hours for a belt speed of 5 m/s.
With the Employer's approval spherical roller bearings may be fitted on Inverted Vee Return
Idlers and Special Purpose Idlers experiencing excessive bearing loads.
Bearings shall be greased for life and purged with an Approved lubricant.
Bearings shall be fitted with outer, non-rubbing multi-labyrinth greased seals. Inner low
friction seals shall be provided on the inner side of the bearing housing to prevent grease
entering the idler interior side except for guide idlers. Additional neoprene weather seal
shall be fitted to the outer idler ends to shed dust and water away from the bearing seals.
4.6.1.3 Rotation
Idlers shall be concentric within the following limits:
• Steel idlers up to 650 mm long – 0.50 mm total indicator reading
• Steel idler over 650 mm long – 0.65 mm total indicator reading
• Rubber disc covered idlers – 1.0 mm total indicator reading.
Idler imbalance shall not exceed 0.056 Nm for rollers up to 152 mm diameter and 0.065 Nm
for rollers with 178 mm diameter.
4.6.1.4 Mounting
Idler frame mounting bolt centers shall be as specified on the Data Sheets. If the idler
manufacturer deems the bolt size and arrangement inadequate for the duty an alternative
configuration may be used with Approval from the Employer.
Idler frames shall be designed to be free of pockets and to shed spillage.
All carry side idler frames shall include a 12 mm diameter hole in each vertical leg to
accommodate pull wire mountings.
Page 16 of 30
The direction of belt travel shall be clearly marked on all troughing and impact idler frames.
4.6.1.5 Stone and Wind Guards
Stone
All idlers shall be supplied complete with stone guards fitted to cover the bearing assemblies
on the outer bearing of outside rollers. The guards shall be designed to prevent dust, water
and small rocks accumulating between the guard and the roller. The fixings should be of a
quality so as to avoid the guard being bent and contacting the roller under strikes from lumps
of ore or the normal running conditions.
Wind
Where required or as specified on Data Sheets and Drawings, wind guards shall be fixed to
the idler frame.
Wind guards shall be manufactured from pressed galvanized mild steel sheet minimum
thickness 1.3 mm and shall be designed to withstand the wind speeds as specified in
MD-101-SMEM-EG-ST-CRT-0001 – Structural Design Criteria for Process Buildings and
Structures.
Wind guards shall be supplied complete with galvanized bolts, nuts and washers and
fabricated with safety edges.
Wind guards shall be bolted to a flat surface on the idler support frames.
Wind guards shall be installed such that the top shall be at least as high as the maximum
height of the material on the belt.
All troughing idler frames shall be drilled to accept wind guards.

4.6.1.6 Shafts
All shafts shall be stationary and manufactured from ductile steel. The shaft shall be
designed and manufactured to possess the strength, rigidity and manufacture quality in order
to fully satisfy the bearings, seal and load requirements for the specified duty.
4.6.1.7 Protective Coatings
Specification, MD-101-SMEM-EG-ME-SPC-0007, Protective Coatings.
Only idler brackets/frames and roller ends are to be painted unless otherwise specified.
4.6.2 Carrying Idlers
4.6.2.1 Trough Idlers
Troughing idler assemblies shall comprise of the following (unless otherwise specified):
• Three (3) roll type idlers for conveyors up to 1800 mm wide
• Five (5) roll type idlers for conveyors over 1800 mm wide.
All idler rollers for each idler set shall be equally rated and interchangeable within a given
belt width.
Troughing idlers shall have the following wing idler angles (unless otherwise specified):
• Standard troughing idler at 35°

Page 17 of 30
• Standard troughing idler set at 45° when installed in the skirted portion of the conveyor,
or in that portion of the conveyor between two or more loading points.
Idler dimensions shall be as specified on Data Sheets.
Troughing idlers for installation beneath skirts shall be of the following type unless otherwise
advised:
• Retractable idlers for conveyors 800 mm wide and below
• Rigid frame drop down type idlers for conveyors 900 mm wide and above. Idler centers
shall be as specified on datasheets.
The rollers shall be completely interchangeable with those on the standard troughing idler
sets. All troughing idlers for installation beneath skirts shall be able to be removed without
removing the feed chute skirting. The design of the retractable or drop down items shall be
of a size and weight that one person can adequately remove. If this requirement cannot be
met an idler removal aid shall be offered and Approved by the Employer.
4.6.2.2 Weighing Idlers
Idler run-out shall not exceed 0.25 mm maximum total indicator reading.
Idler imbalance shall not exceed 0.014 Nm.
The idler construction shall be as required by the weigher manufacturer in order to achieve
the desired weighing accuracy.
4.6.2.3 Transition Idlers
All 5 roll idler sets shall be of the fixed trough-angle type positioned as specified on Data
Sheets. The rollers shall be completely interchangeable with those on the standard troughing
idler sets.
All 3 roll transition idler sets shall be of the adjustable trough-angle type.
4.6.2.4 Training Idlers
Side guide rollers on carry idlers to maintain belt alignment are not preferred and shall be
used only with Approval from the Employer. Instead, crown pulleys and inverted vee roller
sets shall be considered.
Where used training idlers shall be of the self-aligning positive action type. Idler rollers shall
be interchangeable with those on the standard troughing idler sets. Side guide rollers, shall
be easily removable. The centre pivot shall have a roller or ball type bearing suitable for the
induced loads.
The training idlers shall be in the same belt line as the adjacent idlers. Packers shall be
supplied to allow the tracking effect to be changed during commissioning.
The design and construction shall be such that material lumps and fines will not impede the
idler function.
4.6.2.5 Impact Idlers
Impact idlers shall be of the following type unless otherwise advised:
• Retractable idlers for conveyors 800 mm wide and below

Page 18 of 30
• Rigid frame drop down type idlers for conveyors 900 mm wide and above. Idler centers
shall be as per datasheets.
All impact idlers shall be of a heavy duty construction. The rollers shall be of the rubber disc
type unless an alternative is Approved by the Employer. The total idler construction shall
have the strength and stiffness capable of withstanding the impact loading from a continuous
material stream and strikes from individual lumps at critical positions.
The impact idler frames shall be designed at least 25% heavier by weight than the troughing
idlers. The frame shall be constructed in such a way as to allow ease of replacement of idler
rolls, especially the centre idler rolls.
Impact idlers shall have a troughing angle of 45° and the following configurations:
• Three (3) roll type for conveyors of up to 1800 mm wide
• Five (5) roll type for conveyors over 1800 mm wide.
All impact idlers shall be able to be removed without removing the feed chute skirting. The
design of the retractable or drop down items shall be of a size and weight that one person
can adequately remove. If this requirement cannot be met an idler removal aid shall be
offered and Approved by the Employer.
4.6.3 Return Idlers
4.6.3.1 General
Unless otherwise specified all return idlers on 1200 mm belts and above shall be of the twin
roller 'vee type'. Flat idlers may be used to accommodate belt ploughs and scrapers. All
belts less than 1200 mm shall have flat single rolls.
Idler dimensions shall be as specified on Data Sheets.
Flat twin roll carrying idlers shall be installed at both ends of inverted vee idler assembly to
accommodate the belt transition and to support the load imposed by the unsupported length
of belt and/or load imposed due to the installation of belt plough at the tail pulley.
4.6.3.2 Transition
Angles of transition idler sets shall be as specified on Data Sheets.
4.6.3.3 Training
Return training idlers shall be the inverted vee type unless otherwise specified.
Sets shall have vertical servo rollers. Idler rollers shall be interchangeable with those on the
standard return idler sets. Side guide rollers are not preferred and shall be used only when
Approved by the Employer.
The training idlers shall be in the same belt line as the adjacent idlers. Packers shall be
supplied to allow the tracking effect to be changed during commissioning.
The design and construction shall be such that material lumps and fines will not impede the
idler function.
4.6.3.4 Mounting
Mounting bracket dimensions shall be as specified on Data Sheets.

Page 19 of 30
4.7 Belt Magnets

4.7.1 General
Where specified, belt magnets of the cross belt type are preferred. Associated equipment,
such as chutes, belts and supports shall be fabricated from a nonmagnetic material so as to
not affect the performance of the magnet.
The magnet shall be designed to remove all tramp material of size as specified on the Data
Sheets.
4.7.2 Magnet Requirements
Magnets shall be built for continuous magnet energizing and continuous belt cleaning. All
magnets shall meet the duty Specification while operating at the highest ambient
temperature.
A balanced magnetic circuit shall be obtained by having the correct combination of strip
winding, core, back plate and poles.
Magnet coils shall be wound with flat section copper (preferred) or anodized aluminum
double glass insulated conductor.
Steel shall be used in the core, back plate and poles.
Coils shall be immersed in oil and naturally cooled. The maximum oil reservoir temperature
shall not exceed 50°C.
The magnet casing shall be constructed from heavy-duty plate with vertical fins for additional
cooling. The oil reservoir shall include free space to allow for expansion of the hot oil.
4.8 Belt Cleaning
Belt cleaners shall be installed on conveyors in the following locations.
• On the underside of the return section of belt immediately after the head pulley (before
contact with idlers or snub pulleys) so that material removed from the belt will fall into
the discharge chute. Adjustable, spring loaded belt scrapers with ceramic tips are
preferred for this location. Using pairs of belt scrapers is preferred.
• On snub pulleys, located on the ascending side of the pulley about 45° below the
horizontal centre line
• On the upper side of the return section of belt immediately before the tail pulley
(between the tail pulley and the last return idler).
Design of belt cleaners shall be in accordance with CEMA recommendations.

4.9 Chutes
4.9.1 General
All conveyor discharge points shall be provided with head chutes or transfer chutes to direct
material onto the downstream equipment without spillage and also to contain dust which
may be generated within the chute work.
All chute joints shall be flanged, dust tight and bolted. Nuts, bolts and washers required for
flange connection shall be provided and shall be to the grade and size specified on the
Drawings.

Page 20 of 30
Chutes shall be provided with adequate lifting lugs to allow easy installation and removal of
various sections.
Hinged covers, inspection doors and access doors shall be provided on all head and transfer
chutes as shown on the Drawings.
Appurtenances for mounting of pulley scrapers shall be provided on all head chutes.
A double dust curtain shall be provided at the belt entrance to the head chute to contain dust
within the chute.
Rubber seals shall be provided in the following locations:

• Below the return belt, where the belt exits the discharge chute
• Between the carry and return sides of the belt at the entrance/exit of the head chute
• Between the head pulley shaft and the head chute.
Packers shall be supplied for each chute support point and also for chute to skirt flange
connection. Packers shall be full size and to the thickness shown on the Drawings. One
side of the packers shall be slotted to allow insertion with bolts in position. Packers shall be
wired to each appropriate support point for transport.
Head Chutes shall be designed with an impact plate, to accept the ore discharged over the
conveyor head pulley.
Transfer chutes shall be designed to prevent ore discharging directly onto the belt without
first striking micro ledges or an impact plate for high grade lumps and high grade fines.
Material fed onto the belt shall be centralized using an adjustable Vee plate for high grade
lumps and high grade fines.
Design of chute and external reinforcement shall minimize areas where dust and product can
buildup. For example, angle sections shall be turned down to prevent collection of debris.
4.9.2 Guarding
Head, tail and snub pulleys shall be guarded in accordance with ISO 14120. In addition,
guarding shall allow safe access to take up adjustors, bearing vibration testing points, sample
points and all other adjustment points without having to shut down the conveyor.
Guarding shall also protect personnel from pinch points and accidental contact with carry
and return idlers and sampling equipment.
4.9.3 Materials
Chutes and platework materials shall be as specified on Data Sheets and Design Drawings.
Where the Vendor is responsible for design the minimum plate and structural section
thickness shall be 6 mm unless advised otherwise.
4.9.4 Liners
The location, quantity and type of liner plates, billets and other wear protection material
shall be such as to ensure long service life with material flow being precluded on all
unprotected surfaces.

Page 21 of 30
"Dribble" chutes shall be lined with 20 mm ultra high molecular weight polyethylene
material, which shall be installed in accordance with the manufacturer's recommendations.
4.9.4.1 Materials
Liner materials shall be as specified in the Data Sheets and Design Drawings.
Note: Hot working of liner plate material shall not be carried out without the Approval of
the Contractor.
4.9.4.2 Abrasion Resistant Liner Plate Hardness
Abrasion resistant liner plates shall be of minimum Brinell Hardness 500.
4.9.4.3 Surface Finish
The wearing surface of liner plates shall have a maximum surface roughness value Ra of
25 µm.
4.9.4.4 Liner Bolt Holes
Unless otherwise specified, liner bolt holes shall be cored or countersunk to accept bolts
from one side only. The bolt holes shall be designed to accept the specified bolts.
4.9.4.5 Liner Plates – Installation Requirements
Liner plates shall weigh no more than 25 kg.
Unless otherwise specified, the following tolerances shall apply to liner plate dimensions:
• Overall plate size: ± 2 mm
• Bolt hole centers: ± 2 mm
• Bolt hole diagonals: ± 2 mm
Flatness measured on the non wearing surface:

• Maximum convexity: 2 mm in 250 mm
• Maximum concavity: 2 mm in 250 mm.
The overall plate size tolerance shall be measured on the non-wearing side and shall include
any plate squareness errors i.e. all plates shall fit into a true rectangular gauge frame which is
2 mm larger than the specified plate size.
Allowance for draft angles on both the external dimensions and cored holes is acceptable,
however this allowance shall be kept to the practical minimum.
4.9.5 Skirts
All conveyors shall have skirts at each material feed point. Skirts shall prevent material
spillage and shall be of sufficient length to allow material to accelerate to belt speed prior to
reaching the end of the skirt cover.
All skirt components shall be manufactured to the tolerances on the standard Drawings to
ensure interchangeability of like components. Quick release clamp attachments are
preferred for attaching skirts to chutes.
Where specified, nuts, bolts and washers required for flange connections shall be provided
and shall be to the grade and size specified on the Drawings.

Page 22 of 30
A double dust curtain shall be provided at the belt entry end of the skirts and a double dust
curtain shall be provided at the point where material exits the skirts.
Skirt rubber shall be provided along each side of the skirt plate. The width and thickness
shall be as specified on the Standard Drawings. Skirt rubber hardness shall be 43 ± 5 Shore
A durometer hardness.
Skirts shall be fitted with wear plates of the size and type specified on the Standard
Drawings.
Skirts shall be provided with dust covers unless otherwise indicated on the Drawings. Dust
covers shall either be fitted with inspection doors or shall have removable cover sections
with handles and quick disconnects as shown on the Standard Drawings.
If specified on the Drawings, skirt covers shall have provision for dust withdrawal by a dust
collection system.
4.9.6 Fasteners
4.9.6.1 General
All carbon steel fasteners shall be galvanized, unless otherwise noted. Fasteners which may
require disassembly for maintenance, shall have threads coated with an Approved anti-seize
compound.
Unless otherwise specified, where stainless steel bolts or screws are used, nuts shall be of an
Approved dissimilar grade of stainless steel to the bolt or screw, to prevent galling of threads.
4.9.6.2 Chute and Platework Fasteners
Unless Approved otherwise major chute and platework flanged connections shall use as a
minimum, M16 diameter bolts with a minimum material grade of 4.6 in accordance with
ISO 898.1. Unless otherwise noted structural bolts shall be Grade 8.8 in accordance with
ISO 898.1.
4.9.6.3 Liner Fasteners
Unless otherwise specified, liner plate fasteners shall use M20 diameter, countersunk, flat
head, high strength socket screws, with Belleville washers and high strength nuts.
The surface hardness of the liner plate screw heads shall be minimum 90 – 95 Rockwell B.
Where abrasion resistant plastic liner materials – in the form of sheeting – are used, the
method of attachment of the liners shall be as recommended by the plastic liner Vendor and
as Approved by the Contractor.
4.9.7 Painting and Protective Coatings
Specification, MD-101-SMEM-EG-ME-SPC-0007, Protective Coatings.
Areas where site welds are to be undertaken shall be only primed to prevent rusting until
installation. Stainless steel and other non-ferrous surfaces shall not be painted.
Head chutes, transition chutes and skirts shall be painted inside and out before installation of
wear plates.

Page 23 of 30
5. MANUFACTURING/INSTALLATION REQUIREMENTS
5.1 General
5.1.1 Welding
All welding shall comply with the requirements Ma’aden Standard Specification –
MD-101-SMEM-EG-ME-SPC-0009 – Welding. Welding of pulleys shall be subjected to NDT
in accordance with ASME Section V. Shell seam welds and disc-to-shell welds on pulleys
shall be of the full penetration type. Disc to shell welds shall be subject to 100% X-ray NDT.
All connections shall be full penetration butt or fillet welds.
Pulleys with weld connections between end-discs and shell shall be welded from the outside
as well as the inside where the shaft diameter exceeds 120 mm.
No welding is allowed on shafts.
All platework shall be 100% visually inspected and structural joints shall be tested using
Ultrasonic Testing, Magnetic Particle Testing and other techniques as defined in Ma’aden
Standard Specification – MD-101-SMEM-EG-ME-SPC-0009 – Welding.
5.1.2 Bearings
All bearing assemblies shall be packed with grease during assembling (Amount and type of
grease to be specified by bearing manufacturer).
5.2 Conveyor Drives
5.2.1 Gearboxes
The interior of gearboxes shall be thoroughly cleaned and tested for oil tightness prior to
internal painting with oil resistant enamel paint of light color.
Fabricated housings shall be stress-relieved before final matching and guaranteed against
distortion when in service. All gear shafts, except input and output shafts, shall be sealed off
from the outside.
The gears shall be manufactured to a minimum surface finish standard of AGMA level 10 or
better. The forging shall comply with the ultrasonic quality level stipulated as Iscor Level 2
and ASTM E45 Method A Chart 1 for cleanliness of steel.
5.2.2 Couplings
All couplings shall be installed in accordance with the coupling manufacturer’s
recommendations and coupling offset, angular and axial misalignment set within the
manufacturers recommended values.
5.3 Take-Ups
Installation of take-ups shall be in accordance with CEMA recommendations.
Belt installation and splicing shall be in accordance with the manufacturer’s and CEMA
recommendations.
The length of supplied belt shall make allowance for field splices.

Page 24 of 30
Steel cables shall be placed in the belt within a vertical tolerance to maximize cover life and
to minimize wear on pulley lagging. Under non-tensioned conditions, the following
tolerances apply:
• 95% of the cables in any cross-section of the belt shall not deviate vertically by more
than
± 1.5 mm
• No individual cable shall deviate from the nominal cable centerline by more than
± 1.5 mm.
Steel cables shall be placed within a horizontal tolerance to minimize mis-tracking of the
belt. Under non-tensioned conditions, the following tolerances shall apply:
• Cable positions shall not deviate horizontally by more than ± 3 mm from their intended
position in reference to the belt centerline. The intended position of each cable is
defined as the location calculated from the design cable pitch.
• Cable pitch shall not deviate by more than ± 0.5 mm from the design value.
The belt shall have width of edge rubber providing a minimum of 25 mm and a maximum of
35 mm of cover to the edge cable throughout the entire length of belting.
Individual cable tensions prior to and during rubber application shall be within ± 8% of
nominal cable tension.
5.5 Pulleys
5.5.1 Manufacture
Shell plates shall be rolled from structural grade steel plate in accordance with
ASTM A6/A6M.
The preferred material for end discs is structural grade steel plate in accordance with
ASTM A6/A6M, however, if more than one compression ring is fitted to each end of the
pulley, cast steel end discs may be permitted.
Cast steel end discs shall steel in accordance with BS ISO 19960. Alternative cast steels may
be permitted provided that the carbon content does not exceed 0.3% and the tensile yield
strength is not less than 250 MPa. Alternative materials shall not be used without Approval
from the Employer.
All steel plate shall be ultrasonically tested for cracks and delamination prior to use.
Ultrasonic testing shall be carried out in accordance with ASTM A609/609M and the results
recorded for review by the Employer.
Shell plates shall be pre-set to template prior to rolling, allowing sufficient "over set" or
"under set" to ensure a true, circular profile.
The shells shall be straight with both ends square.
After stress relieving, the pulley shall be accurately machined to the dimensions, tolerances
and finish shown on the design Drawings. Deep scores and tool marks shall not be
permitted.

Page 25 of 30
Machined shell tolerances shall be as follows:

• Shell concentricity on steel surface total indicated run out (TIR) – 0.75 mm
• Difference in diameter measured at opposite ends of the shell – 0.8 mm per 1000 mm of
face width.
Ultrasonic checking of the shell plate thickness after final machining shall be carried out
prior to lagging.
5.5.2 Assembly
The shaft, locking system and pulley (and if specified on the Purchase Order, the bearings
and coupling halves) shall be assembled in accordance with the design Drawings. Bearings
shall be fitted within ± 1.5 mm of the dimensioned centers and the drive side bearing within
± 1.0 mm of the distance from the shaft end. The pulley shall be fitted equidistant from the
bearings and within ± 2.0 mm of correct dimension.
Locking elements shall be installed in a dry condition in accordance with the manufacturer's
recommendations. After assembly, the outer end of the element shall be protected with an
Approved sealing compound to prevent corrosion.
The pulley and shaft assembly shall be balanced to run at belt speeds up to 5.0 m per second
without noticeable vibration. Eccentricity over lagging shall be a maximum of 1.5 mm TIR
excluding the adjustments of lagging joining strip.
With the assembly on knife edges, rotated and stopped at random, the torque required to
commence rotation shall not exceed 2.7 Nm. This test shall be applied for one full
revolution of the pulley.
5.5.3 Shaft
All shafting materials shall be ultrasonically tested for cracks prior to machining and the test
results recorded.
All shafts shall be turned and polished to the dimensions, tolerances and finish shown on the
Drawings.
All shafts shall be provided with a tapped hole, drilled on centre line at each end. Tapped
holes shall be for standard eyebolts and shall be drilled and tapped to the dimensions listed
below. Pulley weight shall include shell, hub locking devices, shaft, bearings, half
couplings, end discs and lagging.
Pulley Weight Thread Depth
Up to 1 tonne ¾” UNC 50 mm
1 to 2 tonnes 1" UNC 55 mm
2 to 4.5 tonnes 1.25" UNC 65 mm
4.5 to 6.5 tonnes 1.5" UNC 75 mm
6.5 to 12 tonnes 2" UNC 100 mm
12 to 15 tonnes 2.25" UNC 110

Page 26 of 30
5.6 Idlers
All welds on rollers shall be full penetration, smooth, free from imperfections that may cause
high local stresses and be of a size to accommodate the duty under continuous variable and
static loads.
Installation of idlers shall be in accordance with the manufacturer’s recommendations and

CEMA recommendations.
5.7 Belt Magnets
Installation of belt magnets shall be in accordance with the manufacturer’s recommendations
and CEMA recommendations.
5.8 Belt Cleaning
Installation of belt cleaning devices shall be in accordance with the manufacturer’s
recommendations and CEMA recommendations.
5.9 Chutes
Where high chromium or stainless steel are to be used, the fabricator shall ensure that the
following procedures are employed:
• A dedicated fabrication area shall be set aside exclusively for the fabrication of the alloy
or stainless steel
• All tools and consumables (grinding wheels, welding electrodes, etc) used on the
stainless steel shall not be used on other materials. Cross use shall not be permitted.
• All welds shall be pickled and all worked surfaces shall be pacivated in the appropriate
manner
• Unless otherwise specified, where mild steel is welded to stainless or alloy steel, the
paint system on the mild steel will encroach onto the stainless steel by nominally 50 mm
at all welded connection points.
Plate work shall be fabricated to a tolerance of ± 2 mm and ± 1°. Approval for deviation
from these tolerances shall be subject to Approval by the Employer prior to fabrication.
Local shape deviations such as flat spots, weld discontinuity and peaks shall be limited as
follows:
• Deviations in the vertical welds shall not exceed ± 3 mm
• Deviations in the horizontal welds shall not exceed ± 3 mm.
6. QUALITY
6.1 General
The Vendor shall supply all materials handling equipment in accordance with Ma’aden
Standard Specification – Quality Assurance and relevant documentation in accordance
Ma’aden Standard Specification – Vendor Data Requirements, and shall include the
following submitted as an MDR:
• Inspection and Test Plans (ITPs)
• Material certification
• Procedures for all remedial works

Page 27 of 30
• Welding procedures
• Welding qualifications
• Test results.
6.1.1 Shop Assembly and Testing
The Vendor shall define the extent of shop assembly and testing, and provide certification as
part of the Vendor Data Requirements (VDR). Shop assembly and testing shall include as a
minimum the following activities:
• Factory testing of materials used in the manufacture of the equipment to verify
compliance with the manufacturer’s design standards for chemical composition and
physical properties (i.e. hardness, tensile/compressive strength etc)
• Vendor shall perform a hardness test in accordance with ASTM E10 for each abrasion
resistant component as defined in this Specification. Written results of each test shall be
forwarded for review.
• Welding procedure Specifications for each welding technique shall be prepared by the
Vendor for Approval by the Employer. In addition:
 Welders and welding operators shall be qualified to the following standards:
 AWS D1.1 Steel
 AWS D1.2 Aluminum
 AWS D1.3 Sheet Steel
 AWS D1.6 Stainless Steel.
 The welding work shall comply with the requirements of Section 3 of the relevant
AWS code listed above
 Inspection of welding work shall comply with Section 6 of the relevant AWS code
listed above.
The provision of power supply, services and lubricants for the shop test shall be the Vendors
responsibility.
6.1.2 Site Testing
The Vendor shall assist the Employer with installation, pre-commissioning, commissioning
and performance testing of materials handling equipment, as required in the Contract
Documentation.
6.1.3 Maintenance
The Vendor shall conduct equipment reliability and criticality reviews for each equipment
package with the Employer maintenance personnel. The Vendor shall assist and provide all
life cycle and breakdown frequency data for the Contractor to prepare maintenance
procedures and planning schedules.
Each roll of belting shall be tested in accordance ISO 583 and supplied with a test certificate.

Page 28 of 30
Where required in the Contract Documentation the manufacturer shall witness belt tracking
testing during loaded commissioning. The test shall be conducted in a 150 m low tension
zone near the take-up. With the system both empty and loaded in all operating modes, the
belt edge movement within the nominated section shall not exceed 75 mm. Testing will be
undertaken for a minimum of three full belt revolutions. Alignment of adjacent pulleys and
idlers will be verified to be true. It is not acceptable to misalign pulleys or idlers to correct
mis-tracking.
Surface blemishes shall be minimized. The Vendor shall provide a quality control procedure
for belt cover blemishes, blemish repair and the criteria for rejection of excessive blemishes.
Unacceptable blemish allowance or failure to define blemish QA/QC practice may be reason
to reject the bid.
6.3 Pulleys
All welds shall be stress relieved when T-bottom type end-discs are used.
Non-destructive testing of welds shall be performed as follows:

• Shell longitudinal and circumferential butt welds shall be radiographed for 200 mm from
the ends and 20% in the case of circumferential welds in accordance with ASME V
Articles 2 and 22. Acceptance standard shall be ASME VIII.
• Shell to disc welds shall be ultrasonically tested over 20% of the length, in accordance
with ASME V Articles 4 and 5.
6.4 Idlers
Testing shall be an integral part of the Vendor’s quality control. The Employer may call for
additional testing by destructive and/or ultrasonic and/or X-ray methods. The number of
additional tests and the selection of samples will be determined by the Employer. Tests,
procedures, and inspection or any other requirement called for by the Employer will not in
any way relieve the Vendor of the responsibility for his product to meet the specified duty.
6.5 Chute Liners
A certificate of compliance shall accompany each batch of liners. This certificate shall state
that they comply with the requirements of this Specification and indicate the national
standard to which they have been tested.
The Vendor shall maintain records of the quality testing carried out on each batch of liners /
bolts for a period of five years.
This should include:

• Heat/melt identification code
• Chemical analysis
• Hardness testing
• Quality class (as determined by ultrasonic testing)
• Dimensional tolerances (stating compliance).
These records shall be made available to the Employer if requested.

Page 29 of 30
7. TRANSPORT, PACKAGING, HANDLING AND SHIPPING

All equipment shall be suitably packed to prevent damage during transport, handling and
extended storage on site open to atmospheric conditions. Assemblies shall be wrapped in
polythene, bolted to wooden bases and fully crated.
Adequate provision shall be made for all equipment having components carried in rolling
bearings to avoid damage to the bearings (“brinelling”) during transport. When bearings are
to be removed and rotors blocked for transport, then appropriate shaft locks shall be
provided and fitted.
Rotating parts of assembled components shall be adequately secured to prevent movement

or damage during transport.
Prior to shipping all machined surfaces shall be coated with a corrosion resistant film that is
easily removed by solvents before installation.
Appropriate high visibility label tags shall be fitted to all blocked or locked rotor equipment.
All equipment shall be packed to avoid damage to loose or fragile components during
transport. Equipment sensitive to water damage shall be protected to preserve it in a dry state
for up to six months during transport, storage and installation when subject to heavy, driving
rain.
Assemblies consisting of more than one shipping section shall be supplied with all materials
required for re-assembly at point of destination.
All shipping items shall be:

• Clearly marked to facilitate erection and assembly on site
• Provided with lifting and handling instructions and
• Labeled with the Employer’s address, equipment number (as per the Data Sheets) and
order number.
7.1 Belt Handling

All belting shall be transported in rolls. These rolls shall be secured so as to prevent any
telescoping of the belt either during transportation or storage and installation. The belting in
the rolls shall be continuous i.e. no spliced starter lengths shall be permitted.
The belt reel shall be marked with the direction of unwinding for installation. The top cover
shall be faced to the outside of the roll. The direction of unwinding shall be the direction of
belt travel during normal operations.
7.2 Pulleys
Pulley assemblies shall be protected to avoid damage due to multiple handling and road
transport.
The rubber lagging shall be wrapped with 1.2 mm thick galvanized steel sheet and firmly
strapped. The shaft ends shall be protected by steel strapping and wooden battens.
Where bearing assemblies are fitted to the shaft these shall be adequately protected and
supported to prevent damage or brinelling of the bearings.

Page 30 of 30

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Ma’aden Engineering Manual Rev.

Date: 26 Jul 2011

PROPRIETARY & Materials Handling – Belt Conveyor Systems

4.9.2 Guarding .......................................................................................................................... 21

PROPRIETARY & Materials Handling – Belt Conveyor Systems

2. KEY TERMS AND DEFINITIONS

ANSI American National Standards Institute

ASTM American Society for Testing and Materials

AWS American Welding Society

DOL Direct on Line Motor

HV High Voltage (V > 1000 VAC)

ISO International Standards Organization

ITP Inspection and Test Plan

LV Low Voltage (V ≤1000 VAC)

MDR Manufacturer’s Data Report

NDT Non Destructive Testing

NPT National Pipe Thread

TIR Total Indicated Run Out

Approval Formal confirmation by an authorized person that activities laid

Contractor An entity, engaged or approved by the Employer, entrusted with a

PROPRIETARY & Materials Handling – Belt Conveyor Systems

Employer Saudi Arabian Mining Company (Ma’aden) and its authorized

Vendor An intermediary who supplies manufactured equipment, or

ANSI/AGMA 6010-F97 Spur, Helical, Herringbone and Bevel Enclosed Drives

ASME B16.5 Steel Pipe Flanges & Flanged Fittings

ASTM A484/A484M Standard Specification for General Requirements for Stainless

ASTM A609/609M Standard Practice for Castings, Carbon, Low-Alloy, and

ASTM E10 Test Method for Brinell Hardness of Metallic Materials

PROPRIETARY & Materials Handling – Belt Conveyor Systems

ASTM E709 Standard Guide for Magnetic Particle Testing

AWS D1.1 American Welding Society – Structural Steel Welding Code

BS 1134 Assessment of surface texture. Guidance and general

BS EN 1561 Founding. Grey Cast Irons.

BS ISO 355 Rolling bearings. Tapered roller bearings. Boundary

CEMA Belt Conveyors for Bulk Materials

EN 10204 Metallic Products. Types Of Inspection Documents

ISO 282 Conveyor belts – Sampling

ISO 505 Conveyor belts – Method for determination of the tear

ISO 898-1 Mechanical properties of fasteners made of carbon steel and

ISO 1940 Mechanical Vibration – Balance Requirements

PROPRIETARY & Materials Handling – Belt Conveyor Systems

ISO 4649 Rubber, vulcanized or thermoplastic – Determination of

ISO 14120 Safety of machinery – Guards – General requirements for the

3.2.2 Ma’aden Standards

MD-101-SMEM-EG-CV-SPC-0002 Anchor Bolts

MD-101-SMEM-EG-ME-SPC-0007 Protective Coatings

MD-101-SMEM-EG-EL-SPC-0004 Electric Motors

MD-101-SMEM-EG-ME-CRT-0002 Design Criteria – Mechanical Equipment

MD-101-SMEM-EG-ME-SPC-0002 Mechanical Equipment Installation

MD-101-SMEM-EG-ST-CRT-0001 Structural Design Criteria for Process Buildings and

MD-101-SMPM-PM-QA-PEI-0001 Contractor Quality Requirements

3.3 Site Data

PROPRIETARY & Materials Handling – Belt Conveyor Systems

PROPRIETARY & Materials Handling – Belt Conveyor Systems

The housings shall be of rigid construction, totally enclosed, dust-proof, splash-proof,

PROPRIETARY & Materials Handling – Belt Conveyor Systems

4.2.3.3 Lubrication and Seals

Baseplates shall be designed as self draining.

Coating of baseplates shall be as per equipment data sheet.

Baseplate anchor bolts shall conform with Ma’aden Standard Specification

PROPRIETARY & Materials Handling – Belt Conveyor Systems

The minimum total take-up travel of gravity systems shall be:

The take-up travel of other systems shall be Approved by the Contractor.