TTPS Operation Circle MPM II Unit IV Overhauling of mill, gear box, under bowl, mill outlets, classifier assembly etc in Mills 4A to 4F during forthcoming overhaul

Amount

Charges for draining the oil from mill gear box, cleaning the gear box, worm wheel, worm shaft with neat cloth, arresting of oil leaks and refilling the gear box with old or new oil as directed by the Engineer –in charge, including transportation of material from and to stores and cost of consumables.

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 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

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

Charges for removing (by gas cutting) the eroded spout segments liner from the inner cone and reconditioned the spout segments and refixing the spout segments liner without gap as per the direction of Engineer in charge. This includes the transportation of materials from and to stores and consumables.

Charges for dismantling the wornout spool pipe and MPO (each 4 Nos.) after supporting the relevant coal pipes firmly and disconnecting the victaulic coupling, air line and other accessories and replacing of liner, old /new victaulic coupling gaskets, replacement or inverting the orifice and re-fixing MPO, MDV or spool pipes as per the direction of Engineer in charge. The work includes lead, lift of materials from `0’ meter and devolution of scraps to stores and cost of consumables such as cutting gas, welding electrodes etc.,

Dismantling of worn out classifier assembly, inspection of deflector blade, cleaning, replacing of worn out deflector blade components renewal and assembling of new classifier assembly with its links. The overhauled classifier assembly was checked from 0 to 6 positions and ensured that the deflector blades, links move correspondingly to its position without any malfunction.

Charges for dismantling the centre feed pipe from mill top to transition piece lowering down and placing it in the specified area. Cutting the wornout portion and reconditioning with new/old pipe aligning with the mill and fitting in the correct position as per the direction of Engineer incharge, necessary scaffolding platform and support to be provided by the contractor. This includes consumables and transport of materials from stores and devolution of scrap to stores.

Charges for dismantling the centre feed pipe from mill top to dresser coupling lowering down and placing it in the specified area, cutting the worn out portion and reconditioning with new/ old pipe aligning with the mill and fitting in the correct position as per the direction of Engineer-in-charge, necessary scaffolding platform and support to be provided by the contractor. This includes consumables and transport of materials from stores and devolution of scrap to stores.

Charges for dismantling the worn out lower portion of center feed pipe hoper, lowering the same from about 14mtr level, transportation the new/ reconditioned center feed pipe hoper lower from stores and lifting, fixing the same as per the requirement and as per the direction of engineer in charge. Necessary scaffolding platform and supports to be provided by the contractor. This includes the cost of consumables & hire charges for T&P’s

Charges for dismantling and lowering of wornout vertical discharge coal pipe, changing the eroded pipe portion, collars etc., or replacement of pipe with new/ old distance piece if required and lifting and re-aligning the vertical pipe in the mill as directed by the Engineer incharge. This includes lead, lift consumables such as cutting gas, M.S. Welding electrode etc.

Charges for Removal of worn out side liner assembly and top liners, air intake vanes, etc. and assembling new liners including drawl of new liners from stores and devolution of old liners to stores.

Charges for dismantling of lub oil cooler from Lub oil system, cleaning flushing the cooler oil pipe lines, water pipe lines, oil separator tank, checking of water line valves and nipple, replacement of wornout parts and reassembling the same conducting pressure test of cooler bundle for any tube puncture and plugging if necessary or changing the cooler bundle as per the instruction of site Engineer in charge. Checking of joy coupling L 110 of motor and pump alignment lub oil pump & motor after cleaning the bed portion and adding / removal of necessary shims of necessary conducting trial run after reassembling as per the direction of Engineers incharge including consumables welding electrode, etc.,

Charges for complete painting of mill outer surface upto outlet elbow, tramp iron chute, under bowl, lube oil complete system and cooling water line near LOP system with two coat of good quality of enamel paint, painting the outlet distance pipes, MPO & spool pipes, outlet elbows with two coat of Heat Resisting Aluminium paint after cleaning with wire brush and emery sheet as per the direction of engineer in charge including the cost of paint and consumables etc., For Enamel painting of other mill surface

Charges for complete painting of mill outer surface upto outlet elbow, tramp iron chute, under bowl, lube oil complete system and cooling water line near LOP system with two coat of good quality of enamel paint, painting the outlet distance pipes, MPO & spool pipes, outlet elbows with two coat of Heat Resisting Aluminium paint after cleaning with wire brush and emery sheet as per the direction of engineer in charge including the cost of paint and consumables etc., For HR aluminium painting of coal pipe

Charges for lifting the bowl hub, bowl along with the bull ring segments and vertical shaft by hydraulic jacks, clamping the thrust bearing with fixtures and removal of shims and releasing the jacks, checking blue match, radial run out, back lash as directed by the Engineer incharge, including the cost of consumables.

Charges for fixing of new venturi vane and assembling the venturi outlet assembly, venturi outlet conical collar assembly with coal feed pipe and the mill top.

Charges for dismantling the inner cone assembly from the classifier cylinder by providing chain blocks, dismantling all the bolts and nuts, cutting the cone into three pieces vertically and removing the inner cone through the journal door and devolution of relieved scraps to stores.

Charges for new/ reconditioned inner cone with ceramic tiles, lifting to mill floor [2.5m elevation] providing chain blocks, pull lifts and pushing in the inner cone segments [3 segments] into the mill, lifting, positioning and fixing them with the classifier cone and tightening all bolts and nuts.

Charges for edge preparation of the slanting joints of the 3 segments of inner cone and joining them by welding 3runs with MS electrodes and grinding & finishing the joint portions smoothly.

Charges for dismantling the bowl hub cover, removing all studs in output shaft, removing the bed bolts and dowels of gear box and lifting the bowl by about 60mm supporting the bowl with temporary support, removing the reject hopper with tramp iron chute, removing lube oil inlet & output lines and racking out the gear box from the sole plate through rolls and leading to a position away from the mill bay, as direction by Engineer – in –charges. This including transportation of material from and to stores provision of necessary pulling and lifting machineries, slings, consumables etc.., required for the work.

Charges for leading the gear box from mill bay, installing on the sole plate, fixing of dowels and tightening of bed bolts, lowering the bowl on the gear box output shaft after releasing the temporary supports, fixing and tightening the bowl hub cover, dismantling of the scrapper shoe assembly and refixing with correct clearance, attending to correction works in the under bowl bottom plates & liners, re-fixing the reject hopper and connecting the oil lines and commissioning the gear box.

Charge for removing the gear box top cover after removing the bolts, cleaning the top bearing, checking the clearance,renewal of top guide bearing if necessary and refitting the same as direction by engineer in charge. This includes cost of consumables and T&Ps etc..,

Charges for removing the output shaft from gear box along with upper radial bearing, worm gear with hub, thrust bearing with bearing adopter and radial bearing, keeping in separate stand in position, disassembling the worn out worm gear with hub and all other spares one –by one, cleaning the parts, cleaning the old/new bearing renewal of necessary spares and bearings, reassembling them in the out put shaft as per the direction of Engineer in charge. This includes the transportation of the materials from and to stores and consumables. This includes the T&P hire charges and fixtures of this work.

Charges for removing the worm wheel fixing bolts cleaning the hole refixing and tightening the bolts one by one.

Charges for house keeping of feeder floor at 16m, coal pipe area, mill floor 2.5m,

Champion style 20 & 59 Non metalic graphite asbestos fibre jointing sheets 2000 x 1500 x 3 mm

Champion style 20 & 59 Non metalic graphite asbestos fibre jointing sheets 2000 x1500 x 0.8mm

Bearing No.H 212649 D/H242610 (Upper) and H936340/H 936313 (Lower) Make: NSK)

DURAI ENGINEERING WORKS