MTPS 1 Mill Plant Unit IV Attending the Break down Preventive maintenance works such as overhauling of Gravimetric feeders mechanical face seal assembly renewal of vertical shaft thrust bearing, worm shaft thrust and radial bearing

Amount

Cutting of 10mm thick patches of various sizes and prepare the patches to suit the eroded portions of coal bends, Air restriction ring providing and welding, mill discharge mouth outer surface area welding including devolution of scraps to stores

Charges for hard facing the Airport ring assembly Segments (6 Nos.) and bowl extension rings (6 Nos.) etc. in one mill.

Charges for cutting and removing the existing worn out airport ring assembly and erecting new airport assembly.

Draining of Mill gearbox oil completely, cleaning the gearbox internals like worm shafts and worms wheel. After inspection filling the gearbox with new/old oil including devolution of old oil to stores etc, (Department vehicle will be provided for drawl of oil at free of cost)

Charges for providing wedges between lower skirt and Mill insulation cover plate firmly, removal of gearbox bottom cover flange bolts, lowering the thrust bearing and pump housing after supporting lower radial bearing housing. Lowering the thrust bearings and reassembling of all the above parts, providing SS shims at the bottom cover flange. Blue matching the worm shaft and worm wheel engagement till we get 20 to 50% pattern by trial method releasing/ providing thin SS shim sheet at the bottom cover flange and to get proper running clearance and centering of engagement.

Charges for dismantling the upper skirt and lower skirt assembly Positioning the upper skirt assembly with bowl, by using 2 nos. hydraulic jacks. Fixing 12 Nos clamps (Clamp is to be fabricated in 20 mm MS plate supplied by board) in upper skirt and bowl welding the clamp.

Charges for dismantling and removing worn out thrust bearing of Mill vertical shaft by gas heating the racer, cleaning the bearing seating area in the vertical shaft and assembling back new thrust bearing after heating the racer in oil bath.

Charges for Dismantling of upper skirt assembly, lower skirt assembly, Mechanical face seal assembly, dust guard and blue matching of seal runner, renewal of seal( bronze), air seal, dismantling of Mill bottom cover, upper bearing housing cover, oil seals etc., Complete overhauling, assembling back the lower skirt assembly, scrapper assembly and arresting the oil leakages in the return line and also spillage’s at the rear side of gearbox to prevent Mill fire including cleaning and tapping the threaded holes.

Charges for Renewal of thrust bearing adopter by oil heating and using necessary fixture for assembling the adopter in correct position after positioning the shims below the worm gear hub lock nut. Removing the thrust bearing adopter (worn out) and assembling the new adopter by heating.

Charges for dismantling the gear coupling bolts, gear coupling (worm shaft only), distance piece, unscrewing the worm shaft extension cover bolts and bearing housing cover bolts, removing the worm shaft extension cover, lowering to ground floor, releasing the worm shaft assembly from its position and assemblies providing back the overhauled worm shaft assembly in the gear box and fitting back the worm shaft extension cover, bolting and tightening the bolts to the required torque level and assembling back the gear coupling bolts, distance piece etc.

Charges for checking the bearing clearance after dismantling the thrust bearing and radial bearing housing covers, removing the bushes, springs etc. thoroughly cleaning the bearing housings and other components inspecting the thrust bearings, resetting the axial clearance by reducing the thickness of shims in the thrust bearing housing cover, providing of new shims and by trial method adjusting the clearance to 0.10 mm to 0.15 mm. Assembling back the thrust and radial bearing housing properly and renewing the gland studs and gland packing in the worm shaft assembly.

Charges for changing the worm shaft thrust bearing after gas heating and releasing the old bearings from the worm shaft, heating the new bearing in oil bath and providing the new bearing in the worm shaft in proper Position.(If necessary)

Charges for renewing radial bearing in the worm shaft after gas heating and releasing the old bearing and providing new bearing in the worm shaft after heating the bearing in oil bath. (If necessary)

Charges for checking the axial and radial alignment between the motor and mill worm shaft by making use of 3Nos. dial gauges, mounting the dial gauge fixtures on the shaft and setting the dial gauges on the fixtures and adjusting the motor and completing the alignment within the prescribed .

Charges for changing of worn out scraper pin, push pin cover, Re-conditioning of scrapper, cleaning of under bowl, checking of clearance , inspection and welding of wheels support lugs, wall side liners in mill under bowl.

Charges for removal of choked coal in the gravimetric feeder discharge hopper, center feed pipe by clearing and cleaning of the feeder internals.

Attending the breakdown in Knife Edge gate valve Charges for complete and rectification of defect in knife edge gate valve and renewal of worn-out parts, assembling and checking its operation

Renewal of damaged feeder belt / pulley bearings / half coupling pins Charges for closing the feeder inlet bunker gate valve manually, clearing the coal from down spout pipe assembly dismantling of feeder internals such as pulleys / rollers etc., and replacement of damaged / peeled off feeder belt / pulley bearing / half coupling and its pins and other internals with spare / new one and assembling the same in proper manner and trail run etc.,

Attending Under bowl chock clearing work Charges for inspection of under bowl, cleaning of chocked coal rejects from bowl and under bowl areas and closing the inspection doors by providing gaskets. (During intermediate shut down period).

Removal of foreign materials from feeder areas / Mill upper bowl area ( mill grinding area ) / Mill under bowl area Charges for removal of foreign materials / coal block / stones from feeder areas / Mill upper bowl (Mill grinding areas) & under bowl areas and reject chute mouth areas by cutting and removing the iron pieces.

De-couple the flexible coupling and reassembling Charges for dismantling the existing flexible coupling center piece from the motor and worm shaft ends. If any problem created in the mill motor side for inspection purpose and trail run of mill motor and vibration checking in flexible coupling decouple position after completion of work and assembling the same & trail run etc.

Charges for draining the feeder gear box oil, removing the feeder gear box from position, dismantling the gear box , cleaning the gear box, inspection of bearings, gears, assembling the gear box, oil refilling and fixing in position as per the direction of Engineer in-charge.

Charges for dismantling the motor from seal airline and disposal of accumulated ash & dust and cleaning the bed frames, checking the condition of frames.

Charges for dismantling and assembling the existing impeller from seal airline in mill plant cleaning and inspection of impeller If necessary to replace the damaged parts and after completion of work the same will be assembled in the seal air motor and providing the gland rope with aligning the fan with motor including trial operation.

Charges for complete overhauling of motor including dismantling, cleaning of the stator coils, checking the tightness of the stator wedges and applying one coat of insulating varnish, replacement of both DE and NDE bearings and assembling . Motor capacity: 37 KW.

Charges for cleaning the accumulated coal dust ,fly ash and other waste materials and air washing of the bunker and its platforms, belt beams, lateral surface of the bunker, coal valve area, down spout assembly, feeder and feeder floor, hot air duct and its gate, and damper and platforms, cold air ducts and its gate, damper and platforms & structural areas etc.

Charges for clearing the accumulated coal dust, fly ash and other waste materials and air washing of the feeder discharge chutes and its platforms, structural areas, coal pipes from mill to boiler, Centre feed pipe and its fittings, mill tops, mills, mill floor, below mill floor, gear box areas and ground floor, seal air system, cleaning the oil leakage in gear box area and ground floor etc.,

Cost of MS Welding electrodes

Cutting gas

Cost of hard facing Welding electrodes

M20 X 100 Hex head bolt & Nut (UNBRAKO)

M20 X 120 Socket head cap screw (UNBRAKO)

M8 x 40 countersunk bolt & Nut with washer (UNBRAKO)

Anabond 666

Hyseal compound 30.45 (Dum Dum Putty)

Charges for consumables and T& P’s

SATHISH ENGINEERING (BID ID -1536895)