Replacement of Conveyor Belt and Other Allied Works in Conveyors in Acid Group Plants, FACT-CD.

Replacement of Conveyor Belt and Other Allied Works in Conveyors in Acid Group Plants, FACT-CD.

Replacement of Conveyor Belt of All Widths in Acid Group Plants: The new conveyor belt from 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 conveyor belts is not in the scope of this contract. The conveyor belt shall be released after the curing of the joint / getting clearance. Removed idlers/frames shall be fixed back properly. The trail 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 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 the position in the conveyor line, clean, repair/replace the frame with rollers, and fix them back in position as per instruction. Damaged unrepairable frames shall be transported to the scrapyard.

Replacement of Troughing Idlers : Collect the required materials from the store. Dismantle the damaged/defective idlers from troughing idler frames in the conveyor line. Replace the damaged idlers with new troughing idlers for all sizes of idlers. Damaged idlers 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 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.

Servicing of Troughing/Return Idlers : Dismantle the stuck-up rollers from troughing/return idler frames in the conveyor line. Clean up the accumulations on the idlers and ease them. Fix them back on the idler frames.

Replacement of Conveyor Pulley (Drive, Tail, Snub, Bend and Gravity) : The belt shall be arrested properly with belt clamps after lifting the gravity weight. Decouple the drum from the connected parts and disassemble the sprocket, sensor, and other accessories from the damaged drum. The damaged drum with plummer block and bearings shall be dismantled and taken to the Mechanical workshop. The spare drum shall be transported to the work site from the store/workshop and positioned at the required place. New/Existing Bearings with sleeve and Plummer block at both sides shall be fixed properly with lubricant as per the instruction from the Engineer-in-Charge. Assemble the sprocket, sensor, and other accessories to the replaced drum. The drum shall be aligned and coupled to the connecting part, as per instructions from the Engineer-in-Charge. The Plummer block cover bolts/foundation bolts/jack bolts shall be tightened properly. Release belt clamps, provide required gravity weight, and service the conveyor on load, without any sway.

Replacement of Gearbox/Motor in Conveyors: Decouple the gearbox/motor of the conveyor. Unmount the drive sprocket/coupling half. Dismantle/remove the foundation bolts and jack bolts. Lift and transport the gearbox/motor to the mechanical/electrical workshop for repair. Cleaning of the gearbox/motor shall be done. Transport the spare gearbox/motor to the work site. Erect the motor/gearbox in position. Mount the sprocket/coupling half. Align the motor/gearbox. Full tighten the foundation bolts and jack bolts. Any rework on the jack bolts/foundation shall be done. Couple the motor/gearbox, connect the chain and service the conveyor. Disconnection of the chain in case of gearbox replacement also comes under the scope of this contract.

Replacement of Pulley Bearing with Sleeve and Plummer Block Release the belt tension. Dismantle the foundation bolts of the plummer blocks. Lift the conveyor pulley from the position. Dismantle plummer block halves. Remove the damaged bearing and clean the shaft. Assemble the new bearings with sleeve and lock nut. Lubricate the bearings, and 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. 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, and 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.

Replacement of Plummer Blocks: Release the belt tension. Dismantle the foundation bolts of the plummer blocks. Lift the conveyor pulley from the position. Remove the damaged plummer blocks. Clean up and Lubricate the bearings. Assemble/box up with a new Plummer block. Position back the conveyor pulley. Check the alignment. Any rework on the jack bolts/foundation shall be done. Provide the foundation bolts and fully tighten them. Adjust the jack bolts. Shift the damaged plummer blocks to the scrapyard/area earmarked as instructed.

Replacement of Sprocket with Chain : Remove the chain cover. Disconnect the chain and remove the damaged sprocket from the gearbox/head drum shaft. Collect the spare sprocket from the store/workshop and transport it to the worksite. Mount the sprocket on the gearbox/head drum shaft. Check the alignment and Couple the gearbox and head drum. Lubricate the drive chain and sprockets. Transport the damaged sprocket to the scrapyard.

Servicing/Replacement of Drive Chain : Disconnect and remove the damaged chain from the position/sprockets and clean the chain for inspection. Service the chain by replacing the damaged parts like links, pins, rollers, etc. Replace the entire chain if required/as instructed by the Engineer-in-Charge. Mount back the chain on the sprockets. Lubricate the chain and service the conveyor.

Fabrication and Replacement of Belt Skirt/Scrapers : Collect the required materials from the store. Dismantle the damaged belt skirt board/belt scraper from the position. Fabricate a new skirt board/belt scraper as per the requirement with a new plate, wear strips, etc as per the instructions, and mount it in position. Service the scraper/skirt board without any defects.

Arrangement for Repair/New Splice Joints of Conveyor Belts of All Widths : The arrangements like arresting of gravity take up, idler/frame dismantling, wooden planks fixing, belt supporting, etc. shall be done for splicing / mechanical jointing of the conveyor belt. The activity shall be done when a splicing joint is repaired. Additional belts shall be pulled in (up to 25m) as required after site inspection. Transportation of conveyor belts is in the scope of this activity. Splicing/jointing of conveyor belts is not in the scope of the contractor. The conveyor belt shall be released (gravity take up) after the curing of the joint / getting clearance. Removed idlers/frames shall be fixed back properly. The trail run of the conveyor belt shall be taken on load, without any sway. Scrap conveyor belts shall be transported to the scrap yard after cutting and rolling the same into smaller bundles as per instructions.

Fabrication of Carrying Idler Frames of all Sizes of Belt: Collect the required materials from the store. Fabricate the carrying idler roller frames suitable for all sizes of belts in acid group plants with necessary stiffeners as per the instructions from the Engineer-in-Charge with reference to available drawings/sample frames.

Conveyor Sway Adjustment : Adjust the conveyor sway as per the instruction from the Engineer-in-Charge for all conveyors in acid group plants.

AL GAANAM ENGINEERING WORKS