इंटरनेट मानक

Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to
information for citizens to secure access to information under the control of public authorities,
in order to promote transparency and accountability in the working of every public authority,
and whereas the attached publication of the Bureau of Indian Standards is of particular interest
to the public, particularly disadvantaged communities and those engaged in the pursuit of
education and knowledge, the attached public safety standard is made available to promote the
timely dissemination of this information in an accurate manner to the public.

“जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न' 5 तरफ”

Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru
“The Right to Information, The Right to Live” “Step Out From the Old to the New”

IS 14417 (1996): Bulk handling equipment - Single boom

slewable stacker - Rail mounted - Design, manufacture and
erection - Code of practice [MED 7: Material Handling
Systems and Equipment]

“!ान $ एक न' भारत का +नम-ण”

Satyanarayan Gangaram Pitroda
“Invent a New India Using Knowledge”

“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता ह”

है”
ह
Bhartṛhari—Nītiśatakam
“Knowledge is such a treasure which cannot be stolen”
 IS14417:1996
(Reaffirmed 2001)

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mm
Indian Standard
BULK HANDLING EQUIPMENT - SINGLE
BOOM SLEWABLE STACKER - RAIL
MOUNTED - DESIGN, MANUFACTURE
AND ERECTION - CO.DE OF PRACTICE

ICS 53.080

BUREAU OF INDIAN STANDARDS

MANAK BHAVAN, 9 BAHADUR SIIAH ZAFAR #MARG
NEW DELHI 110002
Bulk Handling Systems and Equipment Sectional Committee, HMD 7

FOREWORD

This Indian Standard was adopted by the Bureau of Indian Standards, after the~draft finalized by the
Bulk Handling Systems and Equipment Sectional Committee had been approved by the Heavy
Mechanical Engineering Division Council.

In industries such as steel, thermal power, cement, etc, uniform quality of the raw material plays
an important role in the quality of the product and also for the optimum operation of the plant.
The raw material is therefore first stacked, blended and then reclaimed for feeding to the plant
for further processing. Stacking is done by stackers. Single boom slewable stacker is a type of
stacker used for this purpose.

Stacker consists of a system of belt conveyors and extendable boom through which material is stacked
in the form of heap. The pile of the material may consist of the same material but in different size
or may consist of different material depending upon requirements. The stacked material is then
reclaimed by reclaimer and loaded onto the conveyor system for feeding to the plant.

For the purpose of deciding whether a particular requirement of this standard is complied with, final
value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in
accordance with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )‘. The number of
significant places retained in the rounded off value should be the same as that of the specified value
in this standard.
 IS 14417 : 1996

Indian Standard
BULK HANDLING EQUIPMENT - SINGLE
BOOM SLEWABLE STACKER - RAIL
MOUNTED - DESIGN, MANUFACTURE
AND ERECTION - CODE OF PRACTICE
1 SCOPE 3.1.2 The slewable stacker shall be designed to take
care of main, additional and special loads in
This standard covers mechanical, structural, accordance with IS 13148 : 1991
electrical, inspection and testing requirements
relating to design, manufacture and erection of rail 3.1.3 The stacker shall be designed and manufac-
mounted slewable stackers. tured to take care of the height, width and centrc
distance~of stockpile(s) of specified parameters
2 REFERENCES required by the user.

The Indian standards listed in Annex A are 3.1.4 The material of construction of the various
necessary adjuncts to this standard. parts of the stacker shall be suitable to handle the
material specified.
SECTION 1 MECHANICAL AND
STRUCTURAL REQUIREMENTS 3.1.5 Safety Against Overturning

3 DESIGN REQUIRMENTS OF SLEWABLE The safety against overturning shall be in

STACKER MECIIANISM accordance with 11 of IS 13148 : 1991

3.1 General 3.1.6 Safety Against Drifting

3.1.1 The main constituents of the stacker consists Safety against drilting shall be in accordance
of: with 12 of IS 13145 : 1991

a) Drive Mechanism: 3.1.7 SafetyAgainst Movement Due to the Wind

1) Long travel mechanism,
2) Discharge boom conveyor drive Independent of the stability against overturning, a
mechanism, check shall be made that the stacker cannot be set
3) Discharge boom - slew mechanism,
in motion by maximum wind increased by 10 per-
4) Boom luffing arrangement, cent. This check shall be carried out assuming a
5) Lubrication arrangement,
coefficient of friction equal to 0.14 for braked
6) Rail clamp mechanism, and wheels and a resistance to rolling of 35 N/10 kN for
7) Power and control cable reeling drum. unbraked wheels mounted on anti-friction bearings
Long travel arrangement; or of 100 N/15 kN for bushed wheels. For the
b)
design of clamps, the co-efficient of friction
C) Under carriage; between the clamps and the rail shall be taken as 0.25.
d) Upper revolving part;
e) Tower structure/pylon; 3.2 Operating Requirements
f) Discharge boom; 3.2.1 Where so specified/required, the operation
g) Counterweight boom; of the various controls shall bc automatic/semi-
h) Machinery house; automatic/manual. Programmable logic controls
j) Operator’s cabin; (PLC) are recommended for automatic and semi-
automatic mode of operation. However, in all
k) Tripper car;
cases, manual override facility shall be provided.
m) Communication and controls; All operations of the stacker including its long
n) Auxiliary and accessories; travel shall be controlled from the operator’s cabin.
1) Dust control system, and Local push button stations shall be provided near
2) Counterweight all drives for repair and maintenance.

1
IS 14417 : 1996

3.2.2 The operator’s cabin shall be pressurised so provided in front of outer wheels. Buffers shall be
as to prevent ingress of dust for which a minimum provided on both sides of the carriage.
water pressure of 5 mm water guage shall be main-
4.1.4 Jacking pads shall be provided for removal
tained inside the cabin. Keeping in view the
and changing of the wheels.
operator’s comfort, 1.5air changes per hour shall be
provided inside the cabin. 4.1.5 The rail gauge shall be decided after taking
into consideration the technical parameters,
3.2.3 Dust control system shall be provided so that
design and the suitability of the machine.
the dust exit to atmosphere shall not exceed 150
mg/m3 or the maximum statutory provisions for 4.2 Boom Conveyor
pollution control, whichever is less. The dust so The conveyor system for boom conveyor
collected shall be fed back to the conveyor system shall generally be designed in accordance with
of the stacker. IS 11592 : 1985 taking operator’s conditions into
3.2.4 In case ofwind velocity exceeding 72 km/h, an account.
audio-visual signal shall be given by the 4.3 Boom Luffhg
anemometer. At 90 km/h, the total power shall be The luffing of the cantiliver discharge boom shall
cut off and automatically, therail clamps along with be with the help of winches/hoists/ hydraulic arran-
brakes shall get operated and applied to all gements. A positive limiting device shall be
motions. provided such that the luffing movement of the
3.2.5 All drive limit switches shall be provided with boom shall not have overrun.
additional back up switches and all brakes shall be 4.4 Operator’s Cabin
fail safe type.
4.4.1 Operator’s cabin with all necessary con-
3.2.6 Provision shall be made to provide two way trols for performing the various operations shall
communication between the stacker operator and be located in such a manner as to ensure complete
central control desk. If so specified, suitable com- view of the operations. Equalizing arrange-
munication system shall also be provided between ments, if required, for cabin may be gravity hang-
the stacker operator and local personnel. ing type or hydraulically operated.
3.2.7 Smoke detectors and fire extinguishers shall 4.4.2 The cabin shall be of adequate size to permit
be provided at suitable locations. entry of and house all the required control
equipment and may contain ample room for its
3.2.8 Adequate illumination shall be provided
adjustment and repair.
near all drives, working/maintenance area of the
machine, material discharge points, MCC rooms, 4.4.2.1’ Control facilities for the following shall be
platforms and walkways, staircases, ladders etc, to provided in the cabin:
enable operation/maintenance of the equipment. a) Stacker travel,
Sufficient number of emergency lights shall be b) Trolley travel,
provided at control room, exit points, ladders, etc.
c) Cabin lighting,
so that during power failure essential activities like
switching off the controls and exit of personnel is d) Dust control system, and
possible. e) An emergency stop button to switch ‘off all
loader motions. This shall not interrupt
4 I)RIVE MECIIANISM power to the auzillary circuits, lighting,
signals, etc.
4.1 Long Travel
4.4.3 Indicators and alarm for main supply, control
4.1.1 The stacker shall be carried on double supply, motions, wind pressure, phase failure, etc,
flanged track wheels arranged for uniform distribu- shall be provided in the operator’s cabin.
tion of loads. The travel motion shall comprise
requisite number of motors, suitably synchronised. 4.4.4 The cabin shall be provided with glazed
Each corner of the stacker shall be provided with windows on all sides to give operator an un-
resilient buffers to absorb the impact. obstructed view of the operations. Electrically
operated wipers for the glass windows shall be
4.1.2 Safety stops shall be fitted on the rail tracks provided to improve visibility during rains.
to limit the travel in addition to limit switches
provided. 4.4.5 The cabin shall be furnished with sufficient
facilities for comfortable seating of the operator
4.1.3 Minimum 50 percent ofwhecls on both sides with height adjustment. The cab shall be fully in-
shall be driven. Rail sweeps to clear rails shall be sulated and shall be equipped with wall mounted

2
 . IS 14417 : 1996

electric motor driven ventilating fan with gravity 5.7.2 The track wheels shall be of steel (cast or
type louvers (see also 3.2.2 and 8.1). forged) or have steel tyres shrunk on and registered.
The steel of track wheels shall not contain more
4.4.6 A signal horn controlled from the operator’s
than 0.060 percent either of sulphur or of phos-
cabin shall also be provided on the stacker.
phorous. The wheel shall be suitably hardened.
5 GENERAL REQUIREMENTS
5.7.3 Rail ?Vreel Size
5.1 A machinery house accommodating drive
mechanisms for operating trolley travel, boom 5.7.3.1 To determine the size of rail wheel, the
luffing and electrical equipment like switch gears, following checks shall be made:
motor control centre, transformer, etc, shall be a) That it is capable of withstanding the maxi-
provided. Adequate space for maintenance and mum load to which it shall be subjected; and
also maintenance facilities like hoist shall be b) That it shall allow the appliance to perform
provided inside machinery house. its normal duty without abnormal wear.
5.2 Wire Ropes and Rope Iknms
5.7.3.2 Diameter of wheels
Wire ropes shall conform to IS 2266 : 1977 and shall
be of best plough steel. Factor of safety shall be as The tread diameters of wheels shall preferably be
per IS 3177 : 1977. standardised to sizes specified in IS 1136 : 1990
commencing at 150 mm, in order of preference
5.3 Bearings specified therein.
All bearings shall be protected against dust and grit. 5.7.3.3 The minimum tread diameter of the
Allowanceshall be made for impact andside thrust. wheel may be calculated from the formula given
Wherever necessary, spherical seatings and below:
separate thrust bearings of suitable dimensions
shall be used. Antifriction bearing used shall have D = ii!f
minimum life of 50 000 working hours. a
where
5.4 Couplings D= tread diameter of wheel in mm,
Flexible couplings shall be of steel or cast iron of w= wheel load in kg, and
suitable grade to withstand transmission of max- a = full width of rail head (face to face)
imum torque developed and shall be including radii in mm.
sized/selected accordingly. For boom conveyor,
high speed coupling shall be fluid coupling in
case of motor rating of 30 kW and above. 5.7.4 Flanges
5.5 Shafts
The dimensions of flanges of track wheels shall
5.5.1 Shafts and axles shall have sufficient strength, be not less than the values given in Table 1. The
rigidity and adequate bearing surfaces. Shafts sub- thickness of flanges of non-guiding wheels, if
jected to cyclic loading shall be designed for fatigue flanged, may be less than the values given in
life also. Table 1 as may be determined by the stacker
manufacturer.
5.5.2 All shafts shall be made of carbon or alloy
steel. Kcyways and splines shall conform to relevant
Table 1 Iilange Dimensions
Indian Standards. \
NI dimensions in millimetres.
5.6 Gears and Gearboxes
Diameter of Depth of Thickness of Guid-
Gears in power operated motion shall be machine Wheels Flange ing Wheel at Flange
Base
cut/ground and shall conform to relevant Indian
Standards. Gear boxes shall have built in lubrica- (1) (2) (3)
tion system either splash or forced type. Up to and 15 15
5.7 Track Wheels including 300

5.7.1 Track wheels may have cylindrical or tapered Over 300 and 20 20
including 500
(conical) treads, with flanges or any other means as
and where. necessary, to guide the stacker effective- Over 500 and 25 25
including 1 000
ly and to prevent derailment. The wheels shall be
mounted in such a manner as to facilitate removal Over 1 000 30 30
and replacement.

3
IS 14417 : 1996

5.8 Bolts, Nuts, Screws and Washers fouling of discharge chute with the skirt board
provided on the boom conveyor during luffing
5.8.1 All bolts and set screws in rotating parts
motion of the boom.
shall be avoided. Bolts in tension shall be avoided
wherever possible. 5.10.3 The feeding arrangement from the tripper
shall be to suit the following requirements:
5.8.2 Tapered washers and tapered pads shall be
- to feed full material on the boom conveyor;
provided on underside of steel sections with
tapered flanges and shall be tack welded in place. - to completely by pass the boom conveyor so
that material can be fed to the same yard
5.8.3 All bolts and nuts shall preferably be in
conveyor, or
accordance with IS 1364 (in five parts) and
- to feed part of material on to the boom
IS 1367 (in eighteen parts). Black bolts and nuts
shall not be used. Alternatively friction grip fitted conveyor and the balance to the stockyard
bolts may be used, where necessary, for proper using flow diverter.
assembly.
6 STEEL STRUCTURES
5.8.1.3 Washers shall conform to IS 2016 : 1967,
IS 5372 : 1975 and IS 5374 : 1974 as appropriate. 6.1 The undercarriage, upper revolving part, dis-
charge boom, pylon counterweight, boom and
5.9 Brakes, Rail Clamps and Anchors structure shall be designed to take care of the
5.9.1 Electra-mechanical (electro-magnetic)/ operational requirements including ease of
electro-hydraulic brakes of adequate capacity shall access and maintenance. The members of the
be provided for all motions/motors in addition to structure shall be designed in accordance with
emergency brakes for hoist hold and hydraulic rail IS 13148 : 1991 to take care of prevalent environ-
clamps. All brakes shall be of fail safe type. Smooth ment conditions.
braking shall be ensured for hoisting and trolley 6.2 Safe means of access shall be provided to the
travel. operator’s cabin and to every place where any
5.9.2 Rail clamps shall be provided and they person engaged on the inspection, repair and
shall be capable of holding the stacker in position lubrication of the stacker shall be called upon to
during maximum wind velocity under storm con- work. Adequate hand holds and foot holds shall
di tions. be provided where necessary. Hand holds and
access opening shall be as per relevant Indian
5.9.2.1 The brakes shall come in automatic Standard(s) where available.
operation from the anemometer.
6.3 Every platform shall be securely fenced with
5.9.2.2 For design of clamps, a coefficient of fric- double tiered guard rails having a minimum
tion between the clamp and rail shall be taken as height of 1.1 m and toe boards unless parts of the
0.25. stacker structure provide safety. The platform
5.9.2.3 Electrical rail clamps shall auto- shall be of sufficient width to enable normal
matically clamp whenever the power supply to maintenance work to be carried out safely. On
the LT motors of the ship loader is cut off. bridge platform which shall not be less than, 0.75
m in width the hand rails shall be provided along
5.9.3 In addition anchoring device shall be the full length of the stacker boom. A toe plate
provided to positively arrest the travelling shall be provided on all platforms to prevent
motion of the stacker under storm conditions. rolling down of materials from platforms.
5.9.4 In case of winch operated luffing arrange-
6.4 Ladders
ments, boom luffing brakes shall be capable of
taking 150 percent of respective full load motor Sides of the ladders shall extend to a reasonable
torque. distance above the platforms or other reliable
5.10 Tripper Car hand holds shall be provided. Ladders shall, if
possible, slope forward. Vertical ladders, exceed-
5.10.1 Suitable tripper car with discharge and ing 3 m in length, shall be provided with safety
feed pulley, idlers, travel wheels, etc, shall be cages.
connected to the main structure of stacker by
means of hinged connection. 7 DISCHARGE MECIIANISM
5.10.2 Discharge chute shall be provided with 7.1 Discharge chute shall be provided with
required liners. Care shall be taken to avoid required liner plates.

4
 IS 14417 : 1996

7.2 Adequate care shall be taken to avoid fouling lubrication system conforming to IS 8593 (in three
of the discharge chute with skirt board provided parts) shall be preferred.
on the boom conveyor during luffing motion.
10.2 If deemed necessary, provision shall be made
7.3 Suitable liner(s) shall be provided for han- at the bearings to vent excess lubricant pressure.
dling, respective material inside the discharge
10.3 Lubricating nipples, pipes and adapters shall
chute.
generally comply with relevant Indian Standards.
8 PRESSURISATION AND DUST
10.4 A lubricating chart shall be provided indicat-
COLLECTION
ing all the lubricating points, the type of lubricant
8.1 Pressurisation and recommended frequency of lubrication.
Operator’s cabin shall be pressurised to prevent 11 POWER FEEDING ARRANGEMENTS
ingress of dust. Pressuring system shall be provided
11.1 Power feeding to the ship loaders shall be
to create a pressure of 5 mm water guage and 15 air
through cable reeJing drums (CRD) with trailing
changes per hour in the machinery house and
cable arrangements. Separate drums for power and
operator’s cabin. All electronic controls provided
control cables shall be provided. The feeding of the
shall be housed in an airconditioned space.
cables to CRD shall be properly guided through
8.2 Dust Control System cable guides to prevent the trailing cable from fall-
ing on the track rails or getting entangled with fixed
8.2.1 The dust control system shall be apable of
structures. Cable tray may be provided below the
collecting completely the dust which is raised from
CRD along its path to prevent cable lying on the
the receiving chute and material transfer points but
ground. However, the provision of cables tray sys-
excluding the discharge point of the stack-
tem shall be optional and is not required in case
er. Facility shall be provided to convey the dust
level ground/floor is available below CRD for each
collected to the ultimate material discharge point.
cable to lie.
8.2.2 Maximum permissible dust loading from the
11.2 Safety limit switches/devices to prevent over
system shall not be more than 25 mg/m3 or the
stretching of cable at the feeding point on the
minimum statutory provisions for -pollution
ground shall be provided.
control whichever is less. Protection against
fire hazard shall be provided for the dust 12 WEATIIER PROTECTION AND PAINTING
collection system when handling hazardous
12.1 All electrical, structural and mechanical
materials.
equipment shall be adequately protected from
9 SAFETY REQUIREMENTS weather. All weather proof covers shall be easily
removable.
9.1 The slewable stacker shall comply with the
relevant safety regulations under the Factories Act, 12.2 The stacker shall be provided with two coats
1948, Indian Electricity Rules and other Statutory of anti-corrosive primer after suitable surface
Regulations, Rules, Acts, etc, as applicable. preparation and final two coats of finish paint to
suit the operating and environmental conditions
9.2 Following essential safety features shall
as specified by purchaser.
be specifically provided:
a) Fire extinguisher and smoke betector alarm 13 LOAD TESTS
system, 13.1 Prior to being placed in service, the stack-
b) Buffers, er shall be tested under overload conditions as
C> Limit switches, given in 13.1.1 and 13.1.2.
d) Anemometer, 13.1.1 Dynamic Test
e) Safety interlocking, The dynamic test shall be carried out with a load of
f-l Rail clamps and anchoring devices, 120 percent of the safe working load. All motions
g> Audio visual alarm, and shall be carefully operated in turn, without check-
h) Guards and cages. ing speeds or temperature rises in the motors.
10 LUBRICATION 13.1.2 Static Test

10.1 Provision shall be made for lubricating all The static test shall be carried out with a load equal
bearings which shall be easily accessible from the to 140 percent of the safe working load. This test
working platforms of the stacker. Centralized shall be carried out under still conditions and

5
IS 14417 : 1996

consists of hoisting the safe working load to small 13.2.8.1 For bushed wheels the above tolerances
distance above the ground and then adding the apply with the wheels in a central position between
required surplus without shock. the wearing plates at either side of the wheel boss.
NOTES 13.2.9 If horizontal guide rollers are used, the
I The values given for these teat loads represent minimum centre of the distance between guide rollers at one
requirements. Where Legislation/Rules or any other corner shall not deviate more than + 1 mm from the
statutory Acts or Requirements call for higher values, these centre axis of the rail (see Fig. 9).
shall be complied with.
2 When making these tests, it is customary to measure the 13.2.10 The diameter tolerance of the wheel shall
deflection of the structure of an unloader. In case, the user correspond to ‘h9’ as per IS 919 (Part 1) : 1993.
wishes to impose a deflection limit, he shall specify this in his
call for tender/enquiry. 13.2.10.1 If runner wheel speeds are synchronized
by an electrical shaft, tighter tolerances may be
13.2 Acceptable Tolerances required.. These shall have to be determined from
case to case.
Acceptable tolerances on trolleys, and tracks
shall be as given in 13.2.1 to 13.2.13. 13.2.10.2 The above tolerance apply to non driven
wheels also as the wheels shall have to be interchan-
13.2.1 The trolley rail-centre distance’s shall not geable.
differ from the nominal dimension by more than
+-3 mm as shown in Fig. 1. , 13.2.11 Recommended tolerances for unloader
tracksare given below. These tolerances apply to
13.2.2 The difference in height of two opposite new unloader tracks. If, in the course of use, these
points of the trolley track perpendicular to the tolerances are exceeded by 20 percent, the track
travel direction of the trolley shall not exceed 0.15 shall be re-aligned. In case the travelling behaviour
percent of the trolley rail-centre distance, with a is noticeably deteriorating, it may be necessary to
maximum of 10 mm as shown in Fig. 2. re-align the track; even if the tolerance excess has
not reached 20 percent.
13.2.3 Trolley rails shall be shall be laid in a way
that the running surface perpendicular to the direc- The greatest divergence ‘A s’ from the span ‘s’ in
tion of the rail is horizontal and that the greatest metres is:
unevenness of the bearing surface is not more than
forss 15m:As= ?3mm
+- 3 mm for rail-centres upto 3 m as shown in Fig. 3.
for s < 15 m : As = & [3+0.25 (s - 15)] mm
13.2.4 The centre of the trolley rail shall not (maximum f 25 mm)
diverge from the centre of the rail girder web by
more than half the thickness of the rail girder web 13.2.11.1 If horizontal guide rollers are provided
as shown in Fig. 4. on one rail only, the tolerances for the other rail
only (rail without guide rollers) may be increased
13.2.5 For lateral straightness of trolley rail, the to three times the abovevalues, but shall not exceed
centre axis of the trolley rail shallnot diverge from 25 mm.
the theoretical centre axis of the rail by more than
13.2.11.2 It is assumed that with the trolley posi-
-t 1.0 mm on a rail length of 2 m. There shall be no
tioned in the centre of the span the deflection of
misalignments at rail joints (see Fig. 5).
both rail tracks shall be approximately equal.
13.2.6 The axis of the wheel axle bores shall be 13.2.11.3 The greatest permissible tolerance of the
within an angular deviation in the horizontal plane
upper edge of the rail shall be +lO mm from the
of -c 0.04 percent from its theoretical position (see theoretical height position. The theoretical height
Fig. 6).
is either the horizontal position or if applicable, the
13.2.7 The axle bores of the wheels opposite to theoretical camber curve. The height position of
each other and if wheels are mounted in bogies, the the two rails may show a divergence of 10 mm. The
axis of the bogies pins of the unwarped trolley and curvature in a longitudinal direction may, at each
unloader bridge shall have an alignment divergence point of a measured length of 2 m, not exceed a rise
in the vertical plane, less than 0.15 percent, maxi- of r2 mm.
mum 2 mm of the trolley wheel centre distance (see 13.2.12 The inclination of the rail rolling surface
Fig. 7). shall not exceed the following values as compared
with the theoretical position (see Fig. 10):
13.2.8 The centres of wheels rolling on a com-
mon rail shall not diverge more than +lmm Longitudinally : 0.3 percent
from the rail centre (see Fig. 8). Laterally : 0.3 percent

6
 IS 14417 : 1996

f-1
f-1

FIG.~ TROLLEYRAILDISTANCE

- S

HORIZONTAL
IJ
HORIZONTAL
0.15 O/o OF s
max 1Omm

FIG.~ HEIGHTDIFFERENCEOFTROLLEY

c+3mm FOR s s 3m
$0.1'10OF s FOR > 3m

FIG.3 RLJNNINGSURFACEOFTROLLEYRAII~S

7
IS 14417 : 1996

FIG.4 CENTREOFTROLLEYRAIL

2.0 m
- C

t
mox 1.0 mm

TROLLEY RAILS

FIG.~ LATEKALSTRAIGHTNESSOFTROLLEYRAIL

THEORETICAL
POSITION OF
ALL WHEELS
I
______
-__---__------I
-------a

!?i!szk
_--------
-_- a-_-_-~

FIG.6 A~ISOFWHEHLA~LEBORES

a
 IS 14417: 1996

0.15a/oOF s

HORIZONTAL

FIG.7 AXLEBORESOFWHEELS

zlmm
! ~ CENTRE AXIS OF THE
I
c. ’ ;1 RAIL HEAD
I‘.’ : .,
1 f I
I /CENTRE OF WHEEL
CENTRE OF W’HEEL \ 1

FIG.~CENTRESOFWHEELSOFSAMERAIL

BETWEEN

DISTANCE BETWEEN
GUIDE ROLLERS

F1c.9 CENTREDISTANCEBETWEENGUIDEROLLERS

13.2.13 For the total length of rail, the maximum SECTION 2 ELECTRICAL REQUIREMENTS
lateral tolerance from a straight line shall be
14 GENERAL
+ 10 mm. The curvature at the longitudinal rail
axis in a horizontal direction shall not exceed a 14.1 The stacker shall be complete with all electri-
lateral deviation of -+ lmm measured at 2 m rail cal accessories required for its safe, smooth and
length (see Fig. 11). efficient operation.

13.2.13.1 For unloaders guided on both sides by 14.2 Only non-hygroscopic materials shall be used
horizontal rollers, the above values shall be valid for insulation.
for the rail surfaces of the horizontal rollers.
14.3 Electrical system offered shall be suitable for
the power supply system fault level at that point.
13.2.13.2 For unloaders guided on one rail only,
the requirement for the straightness of the non- 14.4 Electrical installation work shall be carried
guiding rail may be lowered. out through licensed electrical contractors, holding
valid contractor’s licenses issued by the concerned
13.2.14 For the values in 13.2.1 to 13.2.13, no ac- Statutory Authority and also conforming to
count has been taken for misalignment at the rail relevant standards ofindividual electricals located
joints. It is recommended to use welded rail joints. in the machine.

9
IS 14417:1996

FIG. 10 INCLINATION01; RAIL

2m

FIG. 11 TOLERANCEON TO~~ALLENGTH OF RAIL

14.5All electricals shall be mounted on anti-vibra- service, necessary clearances from live parts may be
tion pads. provided to ensure safety in operation.
15 ENCLOSURES 15.6 All enclosures of electrical equipments shall
15.1All electrical equipment shall be properly be given two coats of anticorrosive epoxy paint over
enclosed or protected to suit the environmental two coats of primer suitable for epoxy.
conditions and to prevent inadvertent or accidental 15.7 Various control gears like contactors, relays,
contact. control transformers, etc, shall be housed in dust
15.2 All enclosures shall preferably be of cast iron proof, damp proof and vermin proof protective
or cast aluminium. Wherever sheet steel has to be panels having doors interlocked with the supply
used, the thickness of the metal shall not be less control switches. Space heaters shall be provided
than 2 mm where enclosures are housed inside a for the panels.
covered area. All exposed outside panels shall have
a metal thickness of not less than 3.15 mm. 16 POWER SUPPLY ARMNGEMENTS

15.2.1Alljoints in enclosures shall be made dust- 16.1 Power supply shall be controlled by a circuit
proof by gaskets of high quality non-deteriorating breaker from which power shall be taken to the
rubber or other suitable material. stacker through suitable collector systems such as
15.3 Bare conductors, if used as bus wires, shall be cable reeling drum, etc.
located so as to prevent any form of accidental
16.2 It shah be possible to trip the circuit breaker
contact. The execution shall ensure complete safety
from the machinery house of the stacker.
and wherever necessary, metallic screens shall be
employed. 16.3 Circuit brcakcr to isolate the main supply to
15.4 Flame proof/increased safety enclosures shall the stacker shall be provided. It shall be possible to
be provided for electrical equipments wherever switch off this breaker from the operator’s cabin.
required. 16.4 A plus and socket arrangement shall be
15.5 Wherever it is necessary for an electrical provided to connect up the stacker’s current
equipment to be adjusted or inspected while in collecting arrangements (power and control).

10
 IS 14417 : 1996

16.4.1 In case of plug and socket arrangement, ing cables shall have copper conductors only. All
power socket shall be interlocked so that the plug control cables shall be 2.5 nrm’copper.
can be withdrawn only when the circuit
20.2 Power and control cables shall be protected
breaker/isolating switch is ‘OFF ‘.
with HRC fuses/circuit breakers.
16.5 External control links shall be taken out of the
20.3 The sizes of the cables shall be so chosen that
stacker using a current collection system similar to
they are rated to carry the full load current
that for power. This system may carry the communica-
continuously after allowing for necessary derating
tion links also.
factors for the conditions of installation, and
17 POWER TRANSFORMERS also so that the voltage drop in cables shall not
exceed 3 percent during running.
Power transformers if provided shall be dry type.
These shall have overload, voltage and tempera- 20.4 All cables shall be neatly clamped at suitable
ture protection. intervals,
18 MOTORS 20.5 All cables shall be terminated by suitable
cable glands.
18.1 To select a motor, the following shall be
established: 20.6 Metallic conduits shall be provided wherever
a) The maximum torque required to produce necessary for the protection of the cables.
motion in the most unfavourable case. 20.7 Power and control cables to the operator’s
b) That it shall allow the stacker to perform its cabin shall be provided with a loop to take care
normal duty without abnormal wear. of movement of cabin during luff operations.
18.2 A.C. motors shall be of totally enclosed, 20.8 Electrical circuits ~may be printed/painted/
fan-cooled weather protected, hose-proof design pasted at the inside of control panel covers.
(IP-55 degree of protection) with at least class B
insulation and shall be suitable for crane duty. 21 EARTIIING

18.2.1 A.C. motors shall have overload and short 21.1 The stacker shall be earthed through shoes
circuit protection. rubbing on the rails. In addition, the connection
between the circuit breaker and the stacker shall
18.3 D.C. motors shall have at least IP-23 have a fourth conductor to be used as an ear-th
enclosure for indoor duty and IP-55 enclosure for connection. The earth connection shall be linked
outdoor duty. to the earth connection of the main circuit
18.4 The motor shall have at least the following breaker.
cyclic duty factors: 21.2 Double earthing shall be provided for all
Trolley travel 60 percent equipments.
Other motions 40 percent 22 LIGIITING
18.4.1 Motors shall have built-in thermistors with
alarm, and shall have space heating elements, either 22.1 The stacker shall be provided with suitable
heating or space heater elements, as specified. illumination to ensure good lighting at all places.

18.5 Thyristor drives if provided shall have cur- 21.2 Flood lights shall be provided at the following
rent limitation, speed limitation, overload points:
protection, short circuit protection and fuse a) On the apron for the operator to see the
protection and preferably rated for Class 4. operation during the night.
b) In front and rear portions of the stacker to
19 RESISTORS
properly light the tracks during stacker
Resistors if provided, shall be intermitent rated travel in the night.
for Class 4 duty and shall be suitable for the
22.3 All lighting circuits shall be protected with
climatic~conditions and the corrosive atmosphere
HRC fuses and shall be controlled by one main
described elsewhere. Stainless steel resistance
switch-fuse in addition to separate circuit control
grids shall be preferred.
switches.
20 CABLES
22.4 Battery operated emergency lights shall be
20.1 All power cables shall be PVC insulated, provided at strategic locations. These shall be the
armourcd and PVC sheathed, flexible type automatic type. The light shall automatically come
preferably with copper conductor. However trail- ‘ON’ when normal power supply fails and shall go

11
IS 14417: 1996

‘OFF automatically when normal supply comes 25.2 Shunt and series limit switches shall be
back. The unit shall incorporate a trickle charger provided for all motions. The shunt switch shall
for keeping the battery on charge. The battery shall operate first and if the motion fails to stop, series
be rated for at least 30 minutes operation. limit switch shall act. Additional limit switches
shall be provided for long travel, trolley travel,
22.5 Air-craft warning/aviation lights shall be
cabin travel, etc.
provided on the stacker if required by any Statutary
Authorities for which separate battery units with 25.2.1 Instead of shunt and series limit switches,
chargers shall be provided. mechanical endlimit switches may be provided. The
22.6 All light fittings shall be mounted on shock preilimit switch shall act first to trip the motor
absorbers. end-limit switch, the breaker on the secondary side
of the transformer shall get tripped. For the trolley
22.7 Low voltage (24V) plug socket outlets, with an additional pre-limit switch shall be provided
hand lamps and sufficient lengths of cables, shall be ahead of the two limit switches mentioned above.
provided.
25.3 Phase failure relay shall be provided to trip
23 CONTROLS the main circuit breaker.
A safe low voltage shall be employed for the
25.5 A warning audio alarmshall be given auto-
controls. This shall be from the secondary winding
matically during long travel operation.
of an isolating transformer; one terminal of this
supply shall be earthed and the contactor and the 26 AIR CONDITIONING
relay coils shall bc connected to this terminal.
In the interest of long life and reliable operation,
24 INTERLOCKS electronic components and other components sen-
sitive to temperature, humidity and dust, shall
24.1 Necessary interlocks for the safe and smooth preferably be located in air-conditioned space(s).
operation of the stacker shall be provided.
27 LIFT
24.2 ‘Forward’ and ‘Reverse’ contactors shall be
An electricalIy operated lift is recommended.
interlooked electrically, and preferably mechani-
tally as well. 28 COMMUNICATION FACILITIES

25 PROTECTION Inter-communication facility within the stacker

structure is recommended.
25.1 In case of wind speed beyond preset level, 29 AUTOMATION
an audio-visual alarm_shall be given in operator’s
cabin to enable the operator to stop the opera- Where considered essential, automation may be
tion of the machine. If the operation is not provided to reduce physical and psychological
stopped, automatic~cut-off of power supply shall stress of operator. Provision shall be kept for over-
be effective beyond a preset higher wind speed. riding automation.

12
 IS 14417 : 1996

ANNEX A
(Clause 2)
LIST OF REFFERRED INDIAN STANDARDS

IS No. Title IS No. Title

919 (Part 1) : 1993 IS0 system of limits and fits: 1367 (Part 5) : 1980 Technical supply conditions
Part 1 Basis of tolerances, for threaded steel fasteners:
deviations and fits (second Part 5 Mechanical properties
revision) and test methods for set
1136 : 1958 preferred sizes for wrought screws and similar threaded
metal ptoducts fasteners not under tensile
stresses (second revision)
1364 (Part 1) : 1992/ Hexagon head bolts, screws
IS0 4014 : 1986 and nuts of product grade A 1367 (Part 6) : 1994/ Technical supply conditions
and B : Part 1 Hexagon head IS0 898-2 : 1992 for threaded steel fasteners:
bolts (size range Ml.6 to Part 6 Mechanical properties
M64) (third revision) and test methods for nuts
1364 (Part 2) : 1992/ Hexagon head bolts, screws with specified proof loads
IS0 4017 : 1988 and nuts of product grade A (third revision)
and B : Part 2 Hexagon head 1367 ( Part 7 ) : 1980 Technical supply conditions
screws (size range Ml.6 to for threaded-steel fasteners:
M64) (third revision) Part 7 Mechanicalproperties
1364 (Part 3) : 1992/ Hexagon head bolts, screws and test methods for nuts
IS0 4032 : 1986 and nuts of product grade A without specified proof loads
and B : Part 3 Hexagon nuts (second revision)
(size range Ml.6 to M64) 1367 (Part 8 ) : 1992 Technical supply conditions
(third revision) for threaded steel fasteners:
1364 (Part 4) : 1992/ Hexagon head bolts, screws Part 8 Mechanical and per-
IS0 4035 : 1986 and nuts of product grade A formance properties for
and B : Part 4 Hexagon thin prevailing torque type steel
nuts (chamfered) (size range haxagon nuts (second
Ml.6 to M64) (third revision) revision)
1364 (Part 5) : 1992/ Hexagon head bolts, screws 1367 Technical supply conditions
IS0 4‘036 : 1979 and nuts of product grade A (Part 9/Set 1) : for threaded steel fasteners:
and B : Part 5 Hexagon thin 1993 / IS0 6157-1: Part 9 Surface discontinuities
nuts (unchamfered) (size 1988 Section 1 Bolts, screws and
range Ml.6 to MlO) (third studs for general applications
revision) (third rev&ion)
1367 (Part 1) : 1980 Technical supply conditions
for threaded steel fasteners: 1367 Technical supply conditions
Part 1 Introduction and (Part 9/Set 2) : for threaded steel fasteners:
general information (second 1993 / IS0 6157-3 : Part 9 Surface discontinuities
revision) 1988 Section 2 Bolts, screws and
studs for special applications
1367 (Part 2) : 1979 Technical supply conditions (third revision)
for threaded steel fasteners:
Part 2 Product grades and 1367 (Part 10) : 1979Technical supply conditions
tolerances (second revision) for threaded steel fasteners:
Part 10 Surface discon-
1367 (Part 3) : 19911 Fasteners - Threaded steel
IS0 898-1: 1988 tinuities on nuts (second
- Technical supply condi-
revision)
tions: Part 3 Mechanical
properties and test methods 1367 (Part 12) : 1981 Technical supply conditions
for bolts, screws and studs for threaded steel fasteners:
with full loadability (third Part 12 Phosphate coatings
revision) on threaded fasteners (second
revision)

13
IS 14417 :1996

IS No. Title IS No. Title

1367 (Part 13) : 1983 Technical supply conditions cranes other than steel work
for threaded steel fasteners: cranes
Part 13 Hot-dip galvanized 5372 : 1975 Taper washers for channels
coatings on threaded fas- (ISMC) (first revision)
teners (second revision)
5374 : 1974 Taper washers for I-beams
1367 (Part 14) : 1984 Technical supply conditions (ISMB) (@t revision)
for threaded steel fasteners:
Part 14 Stainless steel 8593 (Part 1) : 1977 Recommendations for
threaded fasteners (second centralized lubrication as
revision) applied to plant and
machinery: Part 1 Oil lubrica-
1367 (Part 16) : 1979 Technical supply conditions tion
for threaded steel fasteners:
Part 16 Designation system 8593 (Part 2) : 1988 Recommendations for
and symbols (second revision) centralized lubrication as ap-
plied to plant and machinery:
1367 (Part 18) : 1979 Technical supply conditions Part 2 Grease lubrication
for threaded steel fasteners:
Part 18 Marking and mode of 8593 (Part 3) : 1984 Recommendations for
delivery (second revision) centralized lubrication as ap-
plied to plant and machinery:
2016 : 1967 Plain washers (first revision ) Part 3 Aerosol lubrication
2266 : 1989 Steel wire ropes for general 11592 : 1985 Code of practice for selection
engineering purposes ( third and design of belt conveyors
revision )
13148 : 1991 Bulk handling equipment -
3177 : 1977 Code of practicefor overhead Mobile continuous type -
travelling cranes and gantry Rule for design of structures

14
Bureau of Indian Standards

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