SPECIFICATION

POTASH: COMPACTOR EXPANSION BUCKET ELEVATORS ENQUIRY NUMBER: SECTION: 41 12 16 EQUIPMENT SPECIFICATION REV. A, PAGE: 1 OF 10

1.
1.1

SUMMARY OF WORK
The scope of work is outlined in Section 01 11 00, Summary of Work.

2.
2.1

DESIGN CRITERIA
Design Capacity and Process Requirements
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. Design of the equipment shall be in accordance with CEMA.

2.1.1

2.1.2

2.2
2.2.1

Process Description
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. The Compactors Feed the Primary Crushers that feed the Bucket Elevator ES25018, discharging it to the Sizing Primary Screens ES32375, ES32376 and ES32377. After Primary Screening, the Over Size will be discharged in to the Secondary Crusher, the Under Size will 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. 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.

2.2.2

2.2.3 2.2.4

2.2.5

3.
3.1

PIPING REQUIREMENTS
General
Piping shall be designed, inspected, tested and fabricated in accordance with ASME B31.3. 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
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3.1.1 3.1.2

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north-south, then east-west). Pipe threads shall conform to ASME B1.20.1.

4.
4.1

MECHANICAL REQUIREMENTS
General
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. All materials and components used to construct the equipment shall be new and free of defects. Imperial Units shall be used for all dimensions and physical units.

4.1.1

4.1.2 4.1.3

4.2
4.2.1

Equipment Vibration
The general requirements are set forth in Section S01 80 15.19, General Noise & Vibration.

4.3
4.3.1

Materials of Construction
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. 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. All materials shall be new, of the highest quality, type and grade specified. The boot section of all bucket elevators shall be 316L stainless steel. All other casing elements shall be mild steel. 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. 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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4.3.2

4.3.3 4.3.4

4.3.5

4.3.6

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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.
5.1

FABRICATION REQUIREMENTS
Welding
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. 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. Welds shall be thoroughly de-scaled after welding. Post weld heat treatment shall be performed on welded items where required by the Code or called out in the specification. 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.

5.1.1

5.1.2

5.1.3 5.1.4

5.1.5

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4.3.7

Chain links shall be made of high tensile drop forged nickel alloy steel with case hardened chrome alloy steel pins. The Vendor shall confirm material selection where specified. Otherwise the Vendor shall specify materials of construction with corrosion and erosion allowances.

4.3.8

4.4
4.4.1

Specific Equipment Requirements

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 manufacturers 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 L10 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 Owners 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 4.5.1 Motors All electrical motors shall by in compliance with the requirements in this section and in section S26 19 03.11, LV & MV Motors. 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.

4.5.2

4.6
4.6.1

Maintenance Access
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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5.1.6

Forgings shall conform to ASTM requirements for the specified material and shall be heat-treated prior to machining.

6.
6.1 6.2

STRUCTURAL REQUIREMENTS
All structural designs shall adhere to the requirements in this section and in section S01 80 11, Structural Steel. 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.
7.1

ELECTRICAL REQUIREMENTS
The general electrical requirements are set forth in Section S26 00 50, Electrical Requirements For Packaged Equipment. The Vendor shall supply electrical equipment and materials suitable for corrosive ambient conditions due to the presence of KCl, MgCl2 and NaCl solutions.

7.2

8.
8.1

AUTOMATION REQUIREMENTS
The general instrumentation and controls requirements are set forth in Section S25 00 50, General Automation Specification For Packaged Equipment. 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. All instrumentation shall enable interface with Owners DCS, including status for motors. The tail end of all bucket elevators shall be equipped with a zero speed switch.

8.2

8.3 8.4

9.
9.1

NOISE LEVEL REQUIREMENTS

Equipment shall be designed for noise emissions in accordance with Section S01 80 15.19, General Noise & Vibration.

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10. SURFACE TREATMENT AND RUST PROTECTION

10.1
10.1.1

Painting
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. 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

10.1.2

10.2
10.2.1

Rust Protection
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
11.1.1

General
The equipment shall be shop assembled prior to shipment. All critical dimensions shall be verified and all motions checked and tested. The Vendor shall advise procedures and testing programs to be followed to guarantee soundness and integrity of the equipment. The Vendor shall institute and conduct a quality system in accordance with Level B of Section S01 43 00, Quality Assurance and Surveillance. 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.

11.1.2

11.1.3

11.1.4

11.2
11.2.1

Inspection and Testing

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 Owners representative shall have
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reasonable access to the Vendors manufacturing and assembly facilities during the execution of the work. 11.2.2 Each unit shall be mechanically tested in the Vendors premises using the Vendors standard quality control and testing procedures to ensure delivery of a high quality product suitable for the intended application. All tests are subject to witnessing by the Owner. 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: 11.2.5 Final assembly and mechanical run test. Preparation for shipping.

11.2.3 11.2.4

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
13.1.1 13.1.2 13.1.3

Issuance of Documents
The Vendor shall submit drawings and information as specified in Section 01 32 19, Vendor Data Requirements. Vendor shall submit completed datasheets with bid. Vendor shall submit a detailed quality control procedure for review by the Owner/Engineer prior to commencing fabrication. 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.

13.1.4

13.2
13.2.1

Document Review
The Vendors welding procedure and qualification records shall be submitted for approval upon receipt of purchase order.

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13.3
13.3.1

Nameplate
A stamped stainless steel nameplate, containing as a minimum the following information, shall be permanently attached to each piece of equipment. The Owners tag number Vendors purchase order number Vendors 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. 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. A certified statement indicating the above shall be submitted before delivery of equipment to site.

14.1.2

14.1.3

END OF SECTION

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