Overhauling/replacement of damaged components of unit no 04 (WPIL make) VT Pump of 100 cusec discharge alongwith allied works installed at LIS Basantpur

Amount

Overhauling/replacement of damaged components of unit no 04 (WPIL make) VT Pump of 100 cusec discharge alongwith allied works installed at LIS Basantpur (As per scope of work Annexure C of SBD)Overhauling/replacement of damaged components of unit no 04 (WPIL make) VT Pump of 100 cusec discharge alongwith allied works installed at LIS Basantpur by way of: Extraction and Dismantling:- The job involves decoupling of 6.0 kv 1500 HP BHEL make motor coupled with 100 cusec discharge V.T pump by way of disconnecting all the electrical connections from the junction box and LRS of HT motor, dismantling of water lubrication system, dismantling of motor from motor stool by way of unfastening of nuts and bolts from motor stool, decoupling of motor rotor shaft from pump by unfastening rigid coupling, then lifting of motor with the help of heavy duty sling and E.O.T Crane, shifting to the safer place on the spare motor stool for stacking. The job further includes decoupling of rigid coupling from pump shaft, decoupling and extraction of Non Reversible Ratchet assembly with the help of crane and shifting the same to the safer place, lifting of motor stool by unfastening the distance piece, unfastening of T- joint pipe and stacking it in the pump house, extraction of column pipes, diffuser of V.T Pump one by one along with the line shaft, muff coupling including sleeves, cut less bearings with the help of E.O.T crane and shifting and stacking them in the pump house premises. Extraction of complete suction bell/discharge bowl assembly VT pump and then complete dismantling of suction bell, discharge bowl and impeller of VT pump. The job includes cost of skilled/unskilled labour charges and tools and equipments required for the execution of job. Suction bell:- Overhauling of suction bell of the V.T pump involves cutting/rebuilding of badly damaged lower seat of impeller by way of welding, turning, machining to required size for fitting of new C.I. ring fabricated as per shape, size and diameter of the suction bell top for protection guide as shroud & welding with body top of the suction bell for safe guard of impeller ring. Extraction of damaged bearings bush from bearing housing by way of turning on lathe machine using special fixtures for holding heavy/bulky components, rebuilding of the bearing seat and then fitting of newly fabricated bush bearing of required size and specification out of standard material by pressing operation using hydraulic press machine in the bearing housing of suction bell. Rebuilding of damaged portion of suction bell/ arms, caused due to excessive pitting along the internal portion by way of welding with special electrodes. The job involves cost of material, skilled/un-skilled labour charges, to and fro carriage charges etc. Discharge bowl:- Recapitalization of discharge bowl of the VT pump involves re-building the damaged & worn out bearing seat by way of welding with special electrodes and then turning/ machining to the required size/specifications of bearing to be fitted by making special fixtures for holding the heavy /bulky components at both sides. Fitting `of 02 No’s bush bearing of required size and specification out of standard material by pressing operation using hydraulic press machine in the bearing housing of upper and lower seat and then checking alignment. Reconditioning of damaged/worn out upper mechanical seat by way of turning where the neck ring of impeller rotates using special fixtures arrangement making new place for ring of required size. Then fitting of the new ring after fabrication & machining as per the required size by way of welding & machining. Reconditioning of damaged bowl assembly near the joint of suction bell and discharge bowl by way of welding/rebuilding etc. Impeller, Impeller shaft and Top shaft:- Recapitalization of the impeller at the place where impeller seal ring is to be fitted by way of welding with SS electrodes, machining to the required size for proper fitment of seal ring. Re-building of impeller shaft by way of welding with superior quality SS electrodes. Fabrication of 01 no. impeller seal ring out of AISI-410 grade or equivalent steel and then fitting by way of press fitting, Providing of dowels and then welding them using SS electrodes, machining and balancing. Fabrication of 01 nos. SS sleeve as per sample for impeller shaft and impeller bore, and fitting the same by press fitting.The job also involves rebuilding of top shaft keyways and fabrication of S.S keys as per size, shape and specifications. The job involves cost of material, labour charges ,transportation charges and hire charges of tools and tackles etc. Column Assembly & Lineshaft Sleeves/Bearings/Coupling:- The job involves rebuilding of keyways including fabrication of S.S keys and fabrication ,turning/fitting of shaft coupling (Muff-coupling) -04 no’s conforming to S.S or equivalent material as per sample and size. Fabrication and providing of 02 No. SS sleeves out of AISI-410 grade or equivalent material as per sample and size and 03 Nos heavy duty cutless bearings with bronze casing of required size by pressing operation using hydraulic press machine in the bearing housing. The job also involves checking of any wear and tear of all column pipes and providing of repair wherever required and then grinding, painting of column pipes-03 nos, Tee joint pipe- 01 no.,distance piece -01 no. and diffuser pipe/ tapered column pipe -01 no. The job involves cost of material, and labour charges and to and fro carriage charges etc. Assembling And Lowering: - The job involves assembling of V.T pump set by way of assembling discharge bowl, suction bell, suction bell cap, discharge bowl sleeves, (upper and lower), impeller duly fitted with seal rings, sand guard, providing of grease of superior quality. Checking of proper tolerances & fitting of required nos. screws/bolts of 150mm x 25mm dia. Fabrication of sand guard out of bronze material IS 318 Gr- V. Providing of SS bolts (125mmX25mm) along with nuts & washers (60 No’s). After assembling of suction bell, discharge bowl and impeller, lowering of complete assembly, fitting/lowering of tapered column pipe and fitting/lowering further the line shafts (05 no’s) , line shaft sleeves ,shaft couplings and column pipes (03 no’s) one by one up to discharge head and Tee joint pipe fitting with rising main of 48” diameter and fitting of top shaft and then distance piece (4ft length column pipe), then fitting of the same with motor stool and fitting of motor stool on base plate. Providing of consumable items during the lowering operation like cap screws 50mm x 10 mm dia. Cap screws 40mmX10 mm dia., cap screws 25mm x 10 mm dia, cap screws 75 mm x 10 mm dia cap screws100mmX16 mm, providing of brass studs for gland with nuts, steam joint sheet, Dhoti cloth, white lead, emery cloth, “O”- ring nitrite rubber. Fitting of non – reverse ratchet assembly and stuffing box, placing of 6.0 kv 1500 HP (1120kw) motor (BHEL make) on motor stool, checking of alignment of pump and motor using dial gauge,coupling of motor with VT pump set by way of coupling of motor rotor shaft with pump shaft with the help of rigid coupling, making all electrical connections, tightening bolts, providing of gaskets and electrical thimbles. All type of tools and tackles required for executing the work shall be provided by the firm except E.O.T crane, which is to be provided by the department. The Job also includes cost of material, labour charges, hire charges of tools and tackles, transportation charges and then testing & commissioning at site

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