MTPS 1 Mill Plant Unit I Attending the Break down Preventive maintenance works such as overhauling of journal assemblies renewal of vertical shaft thrust bearing worm shaft thrust and radial bearing worn out roller etc

Amount

Charges for dismantling of journal door and roller assembly after disconnecting seal airline and assembling the same as before, after attending works inside the mill & setting ring roller clearance.

Labour chargers for checking / setting spring compression after cleaning the spring compression studs and cleaning or renewal of stop bolt assemblies

Charges for dismantling the old roller from the journal assembly, replacing it with new/old roller including transporting charges from Stores to site and devolution of old rollers to Stores as per the direction of site engineer.

Charges for removal of journal head assembly upper housing, journal shaft with bearings, inspection, cleaning, replacing the worn out parts such as metal clad oil seal, ‘O rings etc. and assembling the above & setting of bearing clearances, filling up of oil, including lead, lift, and devolution of scraps to stores.

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 centring of engagement.

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 .

Dismantling the worn out journal bearings, and re fixing the new bearings.

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

Decouple the flexi able coupling and assembling Charges for dismantling the existing flex able 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.

Cost of MS Welding electrodes

Cutting gas

8mm thick rubber cord

Charges for consumables and T & Ps

RAMASAMY ENGINEERING