ECHP-I- Complete overhauling of rotating parts in drive unit of rotary breaker rectification works in the tire, guide wheel and support wheel, complete alignment works and trail run in the rotary breaker 1B at PCH-I

Amount

Charges for dismantling the Primary Crusher side, top, end cover plate, refuse chute. Leading and lifting Rotary breaker by using hydraulic jack and lowering the refuse chute and bend chute to the Primary Crusher-1B floor by using chain block arrangements etc.,

Charges for dismantling of saddle, scarpering and blue matching, level setting, alignment, replacing wiper strips and assembly work etc

Charges for supporting the spider cone 2 Nos. and dismantling 18 Nos. rail beams, lowering and stacking the rail beam in the ground floor dismantling feed end spider, discharge end spider and lowering the discharge end spider cone into the ground floor including fabrication of necessary supports required.

Charges for lifting the discharge end spider cone/ feed end spider cone from the ground floor to the Primary Crusher floor, moving near to the Primary Crusher bed area with necessary supports etc. including the hire charges for higher capacity crane, special tools and plants etc.

Charges for leading, shifting the tire from PC 1B location to loading point and then unloading the 2 nos tire (OD-2870mm) from crusher floor (20mtr height) to ground floor by using chain block and then loading on to lorry for complete machining the tire at tuticorin local workshop. (outside of TTPS) and providing chain block and rope arrangement and then unloading the 2 nos tire (2870 mm-OD) at loading point of local Tuticorin workshop and leading, shifting to working location and loading the 1no Rotary breaker tire (2870mm-OD) on the heavy duty lathe by loading chain block arrangement and balancing, a centering aligning the tire by using special holding device, fixtures ready for rough area machining work and machining the rough and harden surface of the tire (OD 2870mm face width 152 mm) by operating slow speed of lathe to a smooth surface for metal build up purpose, since the tire surface area was reduced due to uneven wear & tear of tire surface material cost required for metal build up on the machining surface to welding with over coated - S welding electrodes andloading the metal build up wheel for machining on the heavy duty lathe, centering, aligning the wheel and then machining the wheel to suit the OD 2870mm ø by slow speed operation of lathe unloading the 2 no's wheel assembly after machining work from the heavy duty lathe, leading and shifting the job to the loading point and loading the machined 2 no's tire wheel assembly to a department lorry at loading point by using chain block arrangements at Tuticorin local workshop and unloading in primary crusher house-I area inside the TTPS by using chain blocks and after completion of machining the tire, then the tire fitted on both sides and refixing of 40 no's tire fixing clamps and its supports on both sides and supporting arrangements made by using 4 no's chain blocks at each and every corner's of rotor on both sides and heating source given on the tire fixing portion on both sides (drive/ non drive) and then properly fixing of tires on both sides and ovality of tire checking by using dial cage arrangements and finally proper fixing of tires on both sides of PC-1B.rangements made by using 4 no's chain blocks at each and every corner's of rotor on both sides and heating source given on the tire fixing portion on both sides (drive/ non drive) and then properly fixing of tires on both sides and ovality of tire checking by using dial cage arrangements and finally proper fixing of tires on both sides of PC-1B. tire checking by using dial cage arrangements and finally proper fixing of tires on both sides of PC-1B.

Charges for removal of support wheel assembly from the bed and dismantling its assembly by using chain block arrangements etc.,cleaning and storing useful spares in the section store. Loading & unloading the worn out support wheel with shaft from TTPS to work shop. Setting the support wheel with shaft in the lathe and then reduce the bearing seating area by machining the dia 135 mm to 133 mm and 150 mm long. Unloading the support wheel with shaft from lathe and then bring the pulley to a spot where metal to be built up by welding over the machined surface at bearing seating area. Metal build up by welding from133 mm to 137 mm on machined surface on bearing seating area by using special welding electrode. Charges required checking the trueness of the support wheel with shaft Loading the support wheel with shaft from work shop and unloading at TTPS.

Removal of damaged guide wheels on both sides and complete cleaning and overhauling of guide wheels and replacing the worn-out spares and checking the guide wheel freeness etc. Reconditioning of wornout portion in the guide wheel by metal filling with special electrode. The cost data rate for 1 no guide wheel is 4 shifts available proportionately half of the volume need. Hence, we redused 2 shift for 1 no guide wheel.

Charges for fitting the support wheel assembly on the bed, including lifting by using chain block arrangements, measuring, checking, preparing and assembling spares, positioning on bed, checking its alignment etc.

Charges for completely removal of existing damaged RCC concrete structure by chipping, removing the concrete bed frame structure of rotary breaker - 1B drive end side and removal of damaged bed bolt from the existing concrete structure and completely clearing the broken concrete chips around the surrounding of work spot and then fixing the new bed bolt of size 50 mm dia x 300 mm long -5 no's and RTS Rod 10 mm thick to fabrication of concrete bed structure and allied works including cost of hire charges for all T&P’s and cost of consumables etc, complete.

Charges for providing form work for supporting the reinforcement concrete structure by providing RTC steel rod and other allied works. Cutting, bending, tying and fixing etc, then providing RCC concrete 1 : 1½ : 3 using OP cement with 20mm (machine used) (Size of concrete bed 1.61 x 0.4 x 0.25) including cement, all materials, labour, lead, lift and finishing etc., complete.

Charging for strengthening of bed frame structure by welding to improve the bed frame structure by providing stiffness in various sides of bed frame structure. Complete cleaning and inspection and then checking by existing motor bed frames, welding portions by deep groove taken then full welding with one run welding.

Charges for lifting the longitudinal beam from ground floor to Primary crusher floor. Fabrication and erection of cross beam with sufficient supporting erecting the required number of chain blocks including leading, lifting and shifting etc. Assembling of 10 No's rail beams and properly positioned with the existing screen plate at various rows by enlarging the holes and providing bolts and full tightness checking and proper positioning by using chain block, rope etc.,

Charges for alignment with respect to motor with gear box and gear box to motor carried out by proper dial setting and also fabrication of alignment instruments fixing frames etc.,

Charges for loosening & removing the 1 No check nut & tightening of entire M36 X 180 mm HTFG bolts & nuts by using torque wrench. Replace the damaged bolts & nuts. fixing & tightening the castle nuts of PCR. Charges for loosening and removing 1 No self locking nuts checking and tightening of screen plates connecting bolts & nuts of size M 24 by torque wrench. Re-fixing the self lock nut and normalizing PCR.

Checking the face out of rotary breaker rotating sides on drive side by fixing the dial gauge arrangements and then rotating the rotary breaker by using chain block arrangements by step by step (10 rotation). Checking the face out of rotary breaker rotating sides on non drive side by fixing the dial gauge arrangements and then rotating the rotary breaker by using chain block arrangements by step by step (10 rotation). Charge for lifting, levelling and correcting the rotor sides and centering the rotor non drive side and finally proper aligning the rotor.

Charges for Reassembling of rotary breaker housing panels with proper support and renewal of bolts & nuts full tightness checking of Rotary breaker housing panels. (18 No's housing panels - 4m x 1.25m x 10mm) and then proper supporting arrangements made on top portion both side of rotary breaker.

Charges for inspecting and aligning the support wheel position and contact surface of support wheel with spider cone tire by adjusting the bed bolts of support wheels and lock bolts. Conducting trail run of PC-1B.

VEL ENGINEERING