Troubleshooting of Bucket Elevator The bucket elevator is a kind of mechanical equipment used for conveying materials from a lower position to a higher position. This is one of the common mining machinery used in processing industries. It is able to convey large materials size and particles such as coal, cement, sand and rocks. If the Bucket Elevator malfunctions, the source of faulty operation may frequently be found by observing the nature of the fault and applying some simple checks and remedies to correct the malfunction. The following troubleshooting table is provided for this purpose. Trouble Possible Causes Remedy Normal capacity cannot be attained 1.Material is bridging at inlet. 2.Motor not developing operational RPM. 3.Material caked on buckets. 1.Correct method of feeding to insure even feed at elevators rated capacity. 2.Correct power source problem. 3.Clean buckets. Unit stalls or plugs up 1.Belt has too much slack causing buckets to jam. 2.Motor not developing operational RPM. 3.Discharge spout or down spouting plugged. 4.Slipping drive. 1.Make adjustment at take up bolts. 2.Correct power source problem. 3.Check all spouting for foreign material, build-up, dents and turns which may impede material flow. 4.Adjust drive belts and roller chain tension. Noisy operation (i.e. buckets rattling) 1.Elevator out of plumb. 2.Belt too loose or not centered on pulleys. 3.Material caked on pulleys. 4.Damaged or loose buckets. 1.Straighten elevator and plumb. Position braces so elevator is not forced out of alignment when attached to structures which may shift with loading or unloading. 2.Take up belt at splice, re-align and tighten belt with take-up bolts. 3.Clean pulleys 4.Replace or tighten buckets. Pulley drags or does not turn Frozen bearing Lubricate or replace bearing ------------------------------------------------------------------------- Henan Pingyuan Mining Machinery Co., Ltd is the most professional manufacturer of Beltconveyor, and Vibrating screen, Bucket elevator, Screw conveyor, Scraper conveyorusing the world's most advanced technology,we are willing to serve every company to meet your custom needs. our goal is "be the futureglobal leader of mining machinery industry". have any questions, please contact us without anyhesitation.
When it comes to vertically conveying bulk solids, the bucket elevator is unmatched in its capabilities. This diverse, high-capacity machine has become an essential tool at plants handling everything from fertilizers and minerals, to specialty chemicals and aggregates.
The criticality of the bucket elevator is such that when it comes time to replace it, special considerations and precautions must be taken in order to minimize downtime and ensure the best elevating solution is reached.
A wide variety of issues may cause a bucket elevator to operate poorly or below its rated capacity. This might include such things as worn or deformed buckets, slippage of belt on pulleys, improper filing of buckets, and more.
Additionally, many bucket elevators perform inadequately because of their design. Not all elevators are created equal and some designs simply outperform others. Further, the diverse handling characteristics of different materials demand a customized handling solution in most cases. Elevators designed based on a one-size-fits-all approach are often riddled with problems and increased downtime because they were not designed to work with the specific requirements of the material being handled.
Similarly, problems can also result if a significant change in feedstock occurs. Well-designed elevators can quickly become problematic when feedstock parameters change. Some adjustments, like changing belt/chain speed, or switching bucket style or spacing, may be able to resolve the issues, but in some cases, replacement may be necessary, depending on the level of change encountered. In any case, when a change in feedstock occurs, bucket elevator design should be reassessed to ensure optimal performance.
Unless planned for at the time of construction, plants requiring additional capacity usually have to replace their bucket elevator to accommodate the added load. Bucket elevators are available in a wide range of capacities for use in nearly any setting, making the upgrading process fairly straightforward. Elevators may also be over-designed for anticipated operational growth in the future.
A worn or damaged bucket elevator is one of the most common reasons for replacement. Damage may be due to a corrosive material, inadequate or improper maintenance, old age, or a number of other factors.
If at any point a bucket elevator becomes a safety hazard or the structural integrity of the casing has been compromised, and the issue cannot be resolved through repairs, the elevator must be replaced.
As an arterial component of most operations, an out-of-commission bucket elevator can hold an entire operation hostage. To avoid a catastrophic failure during the production schedule, bucket elevators should be preemptively replaced before they have a chance to break down.
Since bucket elevators are a very custom component, replacement can take up to a few months. Preventative replacement will minimize the amount of downtime required for replacement and also avoid the problems associated with an unanticipated outage.
Choosing a new manufacturer for the unit may or may not be necessary. In the case that the original equipment manufacturer (OEM) is no longer in business, or when the OEM did not provide adequate quality or support, there may be a need to select a new OEM. There are many things to factor in to the selection of a bucket elevator manufacturer.
Keep in mind that most OEMs use the same vendors and offer similar casings and sizes, but every OEM has different fabrication designs, shop practices, and standards that can make the difference in the end product. This might include using different casing thicknesses, chain recommendations, take-up seal and design, instrumentation, sprocket vs. traction wheel in the boot, and so forth.
Facilities with the potential for operation growth should consider future capacity needs. As mentioned, elevators can accommodate a larger capacity in the future by designing for the greater needs and running at a reduced capacity in the interim to avoid having to replace the elevator more than once.
Every bucket elevator installation is unique. Because of this, the process of replacing a bucket elevator can vary significantly from one job to the next. To minimize downtime, replacement is best coordinated with a planned outage. Further planning varies widely across each application, with considerations such as foundation requirements, removal of structural steel, additional equipment replacements, and more coming into play.
The chosen manufacturer will require a broad range of data. If only a duplicate unit is desired (with little-to-no required change), and the original manufacturer will be used, this process is fairly simple. In this case, the process may only require reviewing the original drawings to confirm the specifications are still a fit.
In other cases, the bucket elevator manufacturer will require a variety of different data points in order to properly size and spec a replacement elevator. Some of the key data points required include:
The manufacturer will likely make a site visit to verify dimensions before the engineering begins, particularly when tight clearances are involved or the elevator will be passing through several floors of the building. Alternately, detailed drawings may suffice in some cases.
As a critical component in any production setting, replacing a worn out or inefficient bucket elevator requires careful attention to detail. While every installation is unique, considerations such as preventative replacement, improvement of the existing design, and manufacturer selection should all be taken into account.
FEECO is a leading provider of custom bucket elevators and complete bulk material handling systems. All FEECO handling equipment is engineered around the characteristics of the material to be handled and the unique process specifications to ensure an optimal handling solution. All equipment is manufactured to the highest quality standards for a long life of reliable performance. For more information on our bucket elevators, contact us today!
This article from the Aug./July Grain Journal is based on a presentation by Carl Swisher, sales manager, 4B Components Ltd., Morton, IL (309-360-1228), given at the GEAPS Cornbelt and Hoosier chapters 2018 mini-convention, Nov. 13, in Covington, IN.
The centrifugal discharge bucket elevator is very popular in the grain and feed industry for elevating large quantities of bulk material quickly and cost effectively, but when issues arise, it can be difficult to identify the causes.
Scrapes or scratches on plastic elevator bucket side walls indicate belt migration on the pulleys as the buckets are sliding along the side wall of the elevator leg casing. Correct this by leveling the pulley and making sure there are no bent or worn pulley shafts.
Increasing belt tension will keep the belt centered on the crown of the pulley. In rare cases, the belt may not have been cut straight or the mechanical splices not installed at a 90-degree angle from the belt edges.
A bowed out front lip suggests that there is an obstruction inside the bucket elevator or that the belt has not been tensioned properly. Check the throat plate for proper adjustment as well as the clearance of the bucket lip in the boot section. Tightening the belt will make it more taut and reduce any flapping that might allow the bucket lips to scrape the inside of the casing or launch off the pulley.
A worn bucket face that has become thin from excessive wear also is susceptible to being bowed out due to the weight of the product. If the material being elevated is too heavy for standard HDPE buckets, consider installing buckets made from nylon for greater impact tolerance and rigidity.
Although plastic buckets inevitably wear out over time, if the wear is rapid or excessive, the capacity of the bucket will be diminished and replacement will be required. Several causes can drive excessive wear: The input may be too abrasive for the type of plastic being used for the buckets. Switching to a resin with greater abrasion resistance, such as nylon or urethane, may be the solution.
The caking of material in the corners of the boot or casing also can accelerate wear. An alternative to replacing all buckets with a material with greater abrasion resistance is adding a digger bucket every seven to 10 buckets in series. Digger buckets usually are made of steel and fabricated to be 1/4-inch greater in length and projection. Their oversized dimensions break up the crusty or caked material and allow the following plastic buckets to carry the load. It is possible to use a same-sized nylon bucket as a digger with the employment of spacers between the bucket back and the belt to push out the digger the necessary 1/4 inch.
Finally, excessive down-legging can distribute additional material in the boot, causing the bucket to dig through the input more than is necessary. Severe down-legging, or material not making it into the outlet hopper and continuing down the casing, can be caused by a multitude of problems from loose belt tension, to improper belt speed, to the wear of the buckets themselves.
Impact to the bucket often is the cause of cracks between bolt holes. The same goes for fractures along bucket seams. Unless an obstruction can be found within the elevator leg, this usually is a one-time occurrence caused by a foreign object entering the leg.
The most common material used in the production of plastic elevator buckets is high-density polyethylene (HDPE). It is relatively inexpensive, made with FDA-compliant resin, and durable enough for most grain and feed applications.
Polyurethane (urethane) is another engineered resin that offers abrasion resistance but also flexibility and adhesion resistance for applications such as sticky animal feeds, sharp-edged inputs, or high-throughput systems.
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ADRIAN, MISSOURI, US The Occupational Health and Safety Administration (OSHA) on June 29 announced that it has cited a Missouri grain company with six serious safety violations and issued a proposed fine of $215,525 stemming from a Dec. 31, 2020, explosion that seriously injured an employee at MFA Enterprises, operating as West Central Agri Services.
OSHAs investigation of the incident found that the company failed to equip bucket elevators with monitoring devices that notify workers when a belt is slipping, potentially causing friction that could ignite grain dust.
OSHA said it also discovered that the company did not update its dust collection system since it was installed in 1974. Additionally, according to the release, MFA was found to have had workers exposed to falls by allowing them to work on top of railcars to open and close hatches without fall protection.
West Central Agri Services failed to follow industry standards and create company policies for safe grain handling, and needlessly put their own workers in serious danger, said OSHA Regional Administrator Kimberly Stille in Kansas City, Missouri, US. Grain handling hazards can be avoided by using well-known safety measures that are proven to help prevent workers from being injured or killed.
We will have an opportunity to present facts and engage with OSHA as both parties work to resolve the citations, the statement read. We disagree with the characterization that any non-compliance with the regulations was willful. The citation designated as willful represents nearly two-thirds of the published penalties.
MFA Enterprises has active behavioral-based safety programs in place throughout the company, including the Adrian facility. Safety programs and maintenance are a vital component of MFA Enterprises operations at its grain facilities and across the organization. While there has yet to be a final determination of what caused the Dec. 31, 2020, explosion at the West Central grain facility near Adrian, we will be diligent in working with OSHA to resolve the citations. MFA Inc. is one of the regions oldest agricultural cooperatives and is comprised of 45,000 farmers in Missouri and nearby states. The company supplies animal feeds, seed, fertilizer and crop products. The co-op also provides its members with agronomy services, animal health products and farm supplies.
According to Sosland Publishing Companys 2021 Grain & Milling Annual, MFA operates 75 grain storage facilities with a combined licensed storage capacity of 46.4 million bushels, which ranks 38th in North America
As a kind of conveying equipment with simple structure, low maintenance cost and high conveying efficiency, bucket elevator is widely used in food, medical, chemical and mining industries, and plays an increasingly important role.
In the actual conveying operation, the efficiency of bucket elevator is affected by the problems of slipping, deviation, tearing, returning, low production and abnormal noise. In this article, we will tell 12 types of troubles and solutions of bucket elevator, to help you produce efficiently!
Reduce the amount of material feeding, and strive to feed evenly, if after reducing the amount of feeding, still can not improve skidding, it may be that too much material is accumulated in the machine or the hopper is stuck by foreign bodies.
1. When lifting different materials, the speed of bucket is different: when lifting dry powder and granule, the speed is about 1-2 m/s; when lifting bulk material, the speed is 0.4-0.6 m/s; when lifting wet powder and granule, the speed is 0.6~0.8m/s.
If the bucket runs too fast, the material will be unloaded ahead of time, resulting in material return. According to the lifting material, the speed of the bucket should be reduced appropriately to avoid material return.
The hopper is the bearing component of the hoist, which has higher requirements for its materials, so the materials with good strength should be selected as far as possible during installation. The general hopper is made of ordinary steel plate or galvanized sheet welded or stamped.
The solution is to increase the air outlet, that is, to set up the air outlet above the discharge pipe of the elevator head, and the outlet pipe leads directly to the atmosphere to reduce the dust concentration in the head so that it can not produce powder explosion.Get in Touch with Mechanic