Bucket Elevators - Technical Expressions

SPECIFICATION 

POTASH: COMPACTOR EXPANSION SECTION: 41 12 16 

BUCKET ELEVATORS 

EQUIPMENT SPECIFICATION 

ENQUIRY NUMBER: REV. A, PAGE: 1 OF 10 

1. SUMMARY OF WORK 

1.1 The scope of work is outlined in Section 01 11 00, Summary 

of Work. 

2. DESIGN CRITERIA 

2.1 Design Capacity and Process Requirements 

2.1.1 For design information, refer to the equipment data sheets 

in Sections 00 43 45.01, 00 43 45.02, 00 43 45.03, 00 43 

45.04 and 00 43 45.05. 

2.1.2 Design of the equipment shall be in accordance with CEMA. 

2.2 Process Description 

2.2.1 The Product Bucket Elevator, ES25017, conveys material from 

the Existing Bin 28009 to the Recycle Bin ES 28041 that 

feeds a Cascading over flow Chute system which feeds the 

compactors. 

2.2.2 The Compactors Feed the Primary Crushers that feed the 

Bucket Elevator ES25018, discharging it to the Sizing 

Primary Screens ES32375, ES32376 and ES32377. 

2.2.3 After Primary Screening, the Over Size will be discharged 

in to the Secondary Crusher, the Under Size will 

2.2.4 The Dried Product Bucket Elevator, 30-31-070, transfers 

material from outlet of the Product Transfer Drag Conveyor 

to the inlet of the Product Rotary Cooler. 

2.2.5 The Polishing Screen Feed Bucket Elevator conveys material 

from the discharge of the Granular Product Cooler Discharge 

Belt Conveyor to the inlet of the Polishing Screen Feed 

Drag Conveyor. 

3. PIPING REQUIREMENTS 

3.1 General 

3.1.1 Piping shall be designed, inspected, tested and fabricated 

in accordance with ASME B31.3. 

3.1.2 Pipe dimensions shall conform to ASME B36.10 for steel pipe 

and B36.19 for stainless and alloy pipe. Fitting dimensions 

shall conform to ASME B16.9 and ASME B16.11. Pipe flanges 

shall conform to ASME B16.5. Flange bolting shall straddle 

centrelines (vertical, then horizontal for side nozzles and 

PTMFOG0000000184.Doc 

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north-south, then east-west). Pipe threads shall conform to 

ASME B1.20.1. 

4. MECHANICAL REQUIREMENTS 

4.1 General 

4.1.1 All mechanical equipment and components shall be designed 

and supplied in accordance with the requirements in this 

section and in Section S11 00 50, Basic Mechanical 

Requirements. 

4.1.2 All materials and components used to construct the 

equipment shall be new and free of defects. 

4.1.3 Imperial Units shall be used for all dimensions and 

physical units. 

4.2 Equipment Vibration 

4.2.1 The general requirements are set forth in Section S01 80 

15.19, General Noise & Vibration. 

4.3 Materials of Construction 

4.3.1 Materials of construction shall be compatible with the 

process medium and operating environment. All equipment 

components shall be designed such that corrosion and wear 

are minimized. 

4.3.2 All materials specified herein shall be reviewed for 

corrosion and erosion resistance with applicable allowances 

made where required. Wear resistant liners shall be used 

especially at the feed and discharge of the elevator. 

4.3.3 All materials shall be new, of the highest quality, type 

and grade specified. 

4.3.4 The boot section of all bucket elevators shall be 316L 

stainless steel. All other casing elements shall be mild 

steel. 

4.3.5 The buckets as well as the inlet and discharge of the Dried 

Product Bucket Elevator, the Compaction Plant Feed Bucket 

Elevator and the Granular Coarse Product Bucket Elevator 

shall be fabricated from Corten A steel. On the Product 

Bucket Elevator and the Polishing Screen Feed Bucket 

Elevator, these parts may be fabricated from mild steel. 

4.3.6 All buckets shall have a wear lip and be reinforced with a 

3 mm thick metal strip, fully welded on both sides to 

resist filling impact load. 


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located at the centroid, such that the item remains 

vertical and stable whilst being lifted. 

4.6.2.3 Each lifting lug shall be designed to handle the entire 

empty weight of the equipment. 

4.6.2.4 Elevator casing at locations requiring regular inspection 

and maintenance (for example where bearings are located) 

shall be split such that removal of required part of the 

casing is possible without dismantling of external chutes 

and duct work. 

4.6.3 Manways/Access Doors 

4.6.3.1 All man ways shall have a minimum opening of 750 mm. 

4.6.3.2 Permanently installed davits shall be used for man way 

weighing more than 25 kg, where frequent access is 

required. 

4.6.3.3 Manways shall not interfere with other mechanical equipment 

or block access ways when open. 

5. FABRICATION REQUIREMENTS 

5.1 Welding 

5.1.1 Welding shall comply with the requirements of Section IX of 

ASME code and AWS and shall be performed by welders 

qualified and certified in such welding procedures. Welding 

procedures, weld maps and procedure qualification records 

shall be submitted to the Owner/Engineer for review prior 

to the start of fabrication. 

5.1.2 All joints shall be continuous seal welds. No 

interruptions, gaps or exceptions are allowed. All welds 

shall be full penetration, full fusion and free of 

undercut, craters and surface cracks and porosity. 

5.1.3 Welds shall be thoroughly de-scaled after welding. 

5.1.4 Post weld heat treatment shall be performed on welded items 

where required by the Code or called out in the 

specification. 

5.1.5 With the bid, the Vendor shall submit a quality control 

plan detailing roles of different parties, including 

Owner/Engineer. NDE maps and procedures shall be submitted 

by the Vendor for review. 


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SPECIFICATION 





4.3.7 Chain links shall be made of high tensile drop forged 

nickel alloy steel with case hardened chrome alloy steel 

pins. 

4.3.8 The Vendor shall confirm material selection where 

specified. Otherwise the Vendor shall specify materials of 

construction with corrosion and erosion allowances. 

4.4 Specific Equipment Requirements 

4.4.1 General 

4.4.1.1 Vendor shall propose units with as many common components 

as possible. 

4.4.1.2 Bucket elevators shall be continuous discharge, double 

chain bucket type and shall be manufacturer’s standard size 

and design, modified only as required and suitable for duty 

specified. 

4.4.1.3 For each bucket elevator, Vendor shall advise price 

adder/discount schedule for increasing/reducing the height 

of the bucket elevator (+/- 0 to 20%). Price 

adder/discount shall account for all changes required to 

extend/reduce the height of the elevator. This includes 

but is not limited to; drive, power train sizing, shafts, 

bearings, chain, casing, etc. This data will be used to 

finalize pricing of the units before issuing the Purchase 

Order, as layouts are still in development. 

4.4.1.4 Bucket elevators shall be designed with a bucket filling 

rate of 60% by volume at normal operating flow rate and 

using the minimum density of material. Elevator power 

calculation shall be based on buckets filled to 100% of the 

theoretical capacity with maximum density material allowing 

adequate provision for digging load. 

4.4.1.5 Casing design shall be dust-tight and weatherproof. Dusttight 

inspection and repair doors shall be provided as 

required for proper inspection and maintenance. A vent 

connection flange (6” standard pipe flange) for dedusting 

purposes shall be provided at the head and boot sections. 

4.4.1.6 The elevator casing shall be fabricated of steel plate, 

adequately braced and stiffened so as to be completely 

self-supporting. Minimum thickness shall be 6 mm. 

4.4.1.7 The bucket elevators shall be provided with a counterweight 

– type chain tensioning device, complete with weights. 

4.4.1.8 Elevator shall be capable of starting from a full load 

condition, including digging factor. 


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4.4.1.9 An inspection drive shall be provided capable of running 

the elevator at 10 m/min. 

4.4.1.10 Maximum operating speed of the elevators shall not exceed 

CEMA recommendations. 

4.4.1.11 Shaft seals shall be easy replaceable, split felt type. 

4.4.1.12 Chain sprockets shall be segmented in 2 halves. 

4.4.2 Bearings and Bearing Housings 

4.4.2.1 All bearings shall be sealed against water, dust-tight, regreaseable, 

self-aligning, double row spherical roller, 

taper bore type, selected to provide a minimum L 10 

life of 

80,000 operating hours as per the American Bearing 

Manufacturers Association (ABMA), based on the maximum 

speed and axial and radial loads. Radial clearance shall be 

C3 when available. 

4.4.2.2 Bearing seals shall be of the multiple labyrinth or piston 

ring type to protect the bearings from dust and water 

intrusion. A double seal arrangement, with a special cap 

that includes grease channels, a grease fitting and a purge 

hole (grease purge type seal), shall be used. 

4.4.2.3 Owner’s preferred bearing suppliers are: SKF, FAG and 

Timken. 

4.4.2.4 Each shaft shall be supported by 1 (one) fixed and 1 (one) 

floating pillow block bearing assembly. 

4.4.2.5 The floating pillow block bearing shall permit axial 

movement in either direction from the centreline of the 

housing. 

4.4.2.6 The pillow block housing shall be split type and have an 

accurately machined base with slotted holes for mounting 

and adjusting. 

4.4.3 Holdbacks 

4.4.3.1 The bucket elevators shall be equipped with a holdback. The 

holdback shall be mounted on the side opposite to the drive 

side. 

4.4.3.2 Holdbacks must be readily accessible for regular 

inspection, maintenance and replacement. 

4.4.3.3 Holdback selection shall be rated for 2-times the motor 

full load torque. 


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4.4.4 Couplings 

4.4.4.1 Motor to gearbox connection shall be through a fluid 

coupling. 

4.4.4.2 For couplings in general, refer to section S11 00 50, Basic 

Mechanical Requirements. 

4.4.5 Elevator Drive 

4.4.5.1 Drive train, including shaft bearing pillow blocks, shall 

have a separate support independent of the casing. The 

support shall be designed such that all drive loads are 

transferred to the main building structure. For this 

purpose, shafts shall be extended to allow for shaft 

mounting of gear reducer and holdback (on opposite side). 

4.4.5.2 The gear reducers shall be separate units with a torque arm 

fixed to a common, heavy duty, base with the motor. 

4.5 Motors 

4.5.1 All electrical motors shall by in compliance with the 

requirements in this section and in section S26 19 03.11, 

LV & MV Motors. 

4.5.2 Vendor shall obtain specific declaration from the motor 

manufacturer that the selected motor meets all requirements 

such as type of mounting, bearing selection, etc. for the 

duty considered under specified application. 

4.6 Maintenance Access 

4.6.1 General Requirements 

4.6.1.1 Maintenance access shall take into consideration 

appropriate clearances required for equipment removal and 

repair. 

4.6.1.2 Vendor is to define maintenance access required. Platforms 

and stairs will be designed and supplied by Others. 

4.6.2 Removal/Replacement 

4.6.2.1 All equipment, guards and base frames shall be fitted with 

readily accessible lifting lugs, eyes or sling points as 

appropriate for installation, erection and maintenance. 

4.6.2.2 All items of equipment over 25 kg mass shall be furnished 

with lifting lugs for crane handling. Lifting lugs shall be 

positioned to minimise the handling hazards. Where lifting 

attachment points are to be provided, they shall be either 

standard proprietary lifting eyes or custom designed 

lifting lugs. The lifting eyes or lifting lugs shall be 


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SPECIFICATION 





5.1.6 Forgings shall conform to ASTM requirements for the 

specified material and shall be heat-treated prior to 

machining. 

6. STRUCTURAL REQUIREMENTS 

6.1 All structural designs shall adhere to the requirements in 

this section and in section S01 80 11, Structural Steel. 

6.2 The Vendor shall specify maximum reaction forces and 

moments at the sole plates, including suitable design 

factors consistent with construction codes and previous 

experience. 

7. ELECTRICAL REQUIREMENTS 

7.1 The general electrical requirements are set forth in 

Section S26 00 50, Electrical Requirements For Packaged 

Equipment. 

7.2 The Vendor shall supply electrical equipment and materials 

suitable for corrosive ambient conditions due to the 

presence of KCl, MgCl 2 

and NaCl solutions. 

8. AUTOMATION REQUIREMENTS 

8.1 The general instrumentation and controls requirements are 

set forth in Section S25 00 50, General Automation 

Specification For Packaged Equipment. 

8.2 The Vendor shall provide the instrumentation and controls 

necessary for the safe and reliable operation of the bucket 

elevators. This includes instrumentation, local control 

panel or other elements necessary for the operation of the 

equipment supplied. 

8.3 All instrumentation shall enable interface with Owner’s 

DCS, including status for motors. 

8.4 The tail end of all bucket elevators shall be equipped with 

a zero speed switch. 

9. NOISE LEVEL REQUIREMENTS 

9.1 Equipment shall be designed for noise emissions in 

accordance with Section S01 80 15.19, General Noise & 

Vibration. 


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SPECIFICATION 





10. SURFACE TREATMENT AND RUST PROTECTION 

10.1 Painting 

10.1.1 Surface preparation and painting for fabricated steel 

components, including structural elements and plate work, 

shall be as defined in the standard specification Section 

S01 80 15.23, Coating Systems For Steel. 

10.1.2 The following shall not be painted: 

• Underside of base plates supported on concrete 

foundations 

• Stud welded shear connectors 

• Stainless steel and other corrosion-resistant 

materials 

• Machined surfaces 

10.2 Rust Protection 

10.2.1 Prior to shipment, bearings, drive parts, operating 

linkages, etc., shall be covered with a rust preventative 

oil or grease and wrapped with suitable paper to prevent 

entrance of moisture. 

11. SHOP ASSEMBLY, INSPECTION, AND TESTING 

11.1 General 

11.1.1 The equipment shall be shop assembled prior to shipment. 

All critical dimensions shall be verified and all motions 

checked and tested. 

11.1.2 The Vendor shall advise procedures and testing programs to 

be followed to guarantee soundness and integrity of the 

equipment. 

11.1.3 The Vendor shall institute and conduct a quality system in 

accordance with Level B of Section S01 43 00, Quality 

Assurance and Surveillance. 

11.1.4 The approval or review comments of any work by the 

Owner/Engineer and its release shall not relieve the Vendor 

of any responsibility for carrying out the provisions of 

this specification. 

11.2 Inspection and Testing 

11.2.1 The Owner reserves the right to inspect the components at 

any time during manufacturing to assure that the materials 

and the workmanship are in accordance with this 

specification. The Owner’s representative shall have 


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SPECIFICATION 





reasonable access to the Vendor’s manufacturing and 

assembly facilities during the execution of the work. 

11.2.2 Each unit shall be mechanically tested in the Vendor’s 

premises using the Vendor’s standard quality control and 

testing procedures to ensure delivery of a high quality 

product suitable for the intended application. 

11.2.3 All tests are subject to witnessing by the Owner. 

11.2.4 The Owner may inspect the equipment at various stages of 

fabrication, and should be notified 21 calendar days in 

advance, unless otherwise specified, for his representative 

to be present for the following milestones: 

• Final assembly and mechanical run test. 

• Preparation for shipping. 

11.2.5 The Vendor shall certify the tests were performed. 

12. PREPARATION FOR SHIPMENT 

12.1 Refer to General Packing Instructions for details. 

13. DOCUMENTATION 

13.1 Issuance of Documents 

13.1.1 The Vendor shall submit drawings and information as 

specified in Section 01 32 19, Vendor Data Requirements. 

13.1.2 Vendor shall submit completed datasheets with bid. 

13.1.3 Vendor shall submit a detailed quality control procedure 

for review by the Owner/Engineer prior to commencing 

fabrication. 

13.1.4 The Vendor shall submit detailed fabrication drawings for 

review prior to fabrication. This review shall cover 

compliance with the applicable code requirements and 

regulation, general design and dimensions, and shall not 

relieve the Vendor from providing documents with accurate 

design information. 

13.2 Document Review 

13.2.1 The Vendor’s welding procedure and qualification records 

shall be submitted for approval upon receipt of purchase 

order. 


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13.3 Nameplate 

13.3.1 A stamped stainless steel nameplate, containing as a 

minimum the following information, shall be permanently 

attached to each piece of equipment. 

• The Owner’s tag number 

• Vendor’s purchase order number 

• Vendor’s shop order number 

• Equipment serial number 

• Model and size 

• Motor HP and RPM 

• Unit operating RPM 

14. GUARANTEES 

14.1.1 The Vendor shall provide a written Mechanical Guarantee 

that each bucket elevator fulfils all conditions as stated 

in this specification and that it is free from fault in 

design, workmanship, and material. 

14.1.2 Equipment will be subject to performance testing for a 

period of three (3) days. Refer to the General Conditions 

of Contract section for instructions and details. 

14.1.3 A certified statement indicating the above shall be 

submitted before delivery of equipment to site. 

END OF SECTION 


©Hatch 2004/12

Bucket Elevators - Technical Expressions

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