Replacement of Conveyor Belt and Other Allied Works in Conveyors in Acid Group Plants

Replacement of Conveyor Belt of Widths 500mm to 750mm (inclusive) in Acid Group Plants : The new conveyor belt from the CD store/ old usable belt from the site shall be transported and unloaded at the required site. The damaged old belt shall be removed after arresting the gravity take up. The new belt shall be pulled in, full length or part [more than 25 meters] and placed properly to suit with site condition. The arrangements like idler/frame dismantling, wooden planks fixing, belt supporting etc. shall be done for splicing/ mechanical jointing of the conveyor belt. Splicing/jointing of the conveyor belt is not in the scope of the contractor. The conveyor belt shall be released after the curing of the joint /getting clearance. Removed idlers/frames shall be fixed back properly. A trial run of the conveyor belt shall be taken on load, without any sway. Balance belt roll shall be transported to the storage area as instructed by the Engineer in charge. Scrap conveyor belts shall be transported to the scrap yard after cutting and rolling the same into smaller bundles as per instructions. Belt Width: 500 mm to 750 mm.

Replacement of Conveyor Belt of Widths 900mm to 1500mm (inclusive) in Acid Group Plants : The new conveyor belt from the CD store/ old usable belt from the site shall be transported and unloaded at the required site. The damaged old belt shall be removed after arresting the gravity take up. The new belt shall be pulled in, full length or part [more than 25 meters] and placed properly to suit with site condition. The arrangements like idler/frame dismantling, wooden planks fixing, belt supporting etc. shall be done for splicing/ mechanical jointing of the conveyor belt. Splicing/jointing of the conveyor belt is not in the scope of the contractor. The conveyor belt shall be released after the curing of the joint /getting clearance. Removed idlers/frames shall be fixed back properly. A trial run of the conveyor belt shall be taken on load, without any sway. Balance belt roll shall be transported to the storage area as instructed by the Engineer in charge. Scrap conveyor belts shall be transported to the scrap yard after cutting and rolling the same into smaller bundles as per instructions. Belt Width :900 mm to 1500 mm.

Replacement of Troughing Idler Frames And Self Aligning Idler Frames With Rollers Of All Sizes : Collect the required material from the store/ workshop. Dismantle the defective idler frames with roller from position in the conveyor, clean, repair/replace the frame with rollers and fix back in position as per instruction. Damaged unrepairable frames shall be transported to the scrapyard.

Replacement of Troughing Rollers : Collect the required materials from the store. Dismantle the damaged/defective rollers from troughing idler frames and replace the damaged rollers with new troughing idler rollers for all sizes of rollers. Damaged rollers shall be transported to the scrapyard as instructed.

Replacement of Return Idlers with Clamps: Collect the required materials from the store. Dismantle the damaged/defective return idlers and clamps from the position, clean, repair/replace the idlers with new clamps as per instruction from the Engineer in charge for all sizes of idlers. Damaged idlers shall be transported to the scrapyard as instructed.

Replacement of the Conveyor Pulleys - Type I : Collect the required materials from the store/ workshop. The belt shall be arrested properly with belt clamps, after lifting the gravity weight. Disconnect the sensors, chain, sprocket and other accessories from the Drum Pulley shaft. The damaged drum pulley with plummer block and bearings shall be dismantled from the line and taken to the Mechanical workshop. A New/Serviced drum shall be transported to the work site and positioned at the required place. New/ Existing bearings with sleeves and plummer block at both sides shall be fixed properly with lubricant. Assemble the sprocket to the drum pulley and align the same with the motor sprocket in case of Driving/Head Drum Pulley. The drive chain, sensors and other accessories shall be provided. The Plummer block cover bolts/foundation bolts/jack bolts shall be tightened properly as per instructions from the engineer in charge. Any repair works, if needed shall be done as per requirement. Release belt clamps, provide required gravity weight and service the conveyor with load, without any sway. Dismantling of existing Bearings and sleeves comes under the scope of this contract. Conveyor Drum pulley Type I : All Driving/Head Drum Pulleys in Acids Plants, All conveyor drum pulleys of R6, R9, and G1 conveyor.

Replacement of Conveyor Pulleys - Type II : Collect the required materials from the store/ workshop. The belt shall be arrested properly with belt clamps, after lifting the gravity weight. Disconnect the sensors and other accessories from the Drum Pulley shaft. The damaged drum pulley with plummer block and bearings shall be dismantled from the line and taken to the Mechanical workshop. A New/Serviced drum shall be transported to the work site and positioned at the required place. New/ Existing bearings with sleeves and plummer block at both sides shall be fixed properly with lubricant. Assemble the sensors and other accessories to the drum pulley. The Plummer block cover bolts/foundation bolts/jack bolts shall be tightened properly as per instructions from the engineer in charge. Any repair works, if needed shall be done as per requirement. Release belt clamps, provide required gravity weight and service the conveyor with load, without any sway. Dismantling of existing Bearings and sleeves comes under the scope of this contract. Conveyor Drum Pulley Type II: All non drive conveyor drum pulleys except R6, R9 & G1 conveyors.

Replacement of Pulley Bearing with Sleeve and Plummer Block : Collect the required materials from the store/ workshop. Release the belt tension. Dismantle the foundation bolts of the plummer blocks. Lift the conveyor pulley from position. Dismantle plummer block halves. Dismantle the damaged bearing. Clean the shaft. Assemble the new bearings with sleeve and lock nut. Lubricate the bearings. Assemble/box up the Plummer block. Replace the plummer block if required/as instructed by the engineer in charge. Position back the conveyor pulley. Check the alignment. Provide the foundation bolts and fully tighten them. Adjust the jack bolts and service the conveyor with load, without any sway Shift the damaged bearings to the scrapyard/area earmarked as instructed.

Servicing of Pulley Bearings : Release the belt tension and open the bearing cover. Remove the contaminated lubricant from the bearing. Inspect the bearing. Clean the bearing and its seat. Apply fresh lubricant. Box up the Plummer block and service without defect. Check the foundation bolts and jack bolts.