Roller removing evagination system

          Roller removing evagination tool installation system

ROLLER EVAGINATION SYSTEM INSTALLATION & TESTING Contents SCOPE:................................................................................................................................................. 1 MINIMUM MANPOWER: ................................................................................................................. 2 MINIMUM TOOLS LIST ....................................................................................................................3 MINIMUM CONSUMABLE LIST .................................................................................................... 3 PRICE BID........................................................................................................................................... 3 RESPONSIBILITY MATRIX: ............................................................................................................ 4 

 SCOPE: 

 1. Upon receiving PTW and isolation cross verifications, the connecting flange between hot PA duct and mill body is to be opened and dummy flange to be inserted. 

 2. All manholes, inspection doors in the mill are to be opened. Coal cleaning to be carried out from the grinding table, scrapper chamber and inlet duct. 

 3. Location for installation of roller evagination access door will be marked by EIC. The marked area on the mill body (housing) and the classifier to be cut using oxyacetylene gas cutting set to precision. Prior to cutting out section from the mill body, internal cross stiffeners to be provided (welding) at locations identified by EIC to avoid any deformation in shape during cutting and while re-welding of the access door. 

 4. Making a cut-out on the classifier body in line (vertical) by 100mm in order to create space for accommodating the loading frame when lifted from position ( detailed location and activity will be explained at the time of site visit). 

 5. Positioning and Welding of cantilever tool supporting seat on the bottom housing at the location marked by EIC. 

 6. Installation of roller extraction shaft plumber blocks with base frame on the housing. 

 7. Cutting out existing static nozzle ring at the area near the roller evagination door and installing segmented static nozzle ring in place. 

 8. Welding of access door frame, door hinges and installation of access door. Ensuring verticality and position of the door is in-line with the welded frame. 

 9. All associated drawing with weight chart will be put out for understanding at the time of on-site discussion

MINIMUM MANPOWER: S NO. POSITION NOS MIN. EXPERIENCE 1 Supervisor 2 >6yrs 2 Rigging Foreman 1 >15yrs 3 Senior Fabricator 2 >10yrs 5 Junior Fitter 2 >3yrs 6 Welder ‘6G’ 4 >6yrs Gas Cutter 2 7 Rigger 4 >6yrs 8 Helper 3 >4yrs TOTAL 20 Note: Contractor shall have minimum of 10 years of experience in overhauling activities associated to VRM coal mills in power plants of capacity not less than 200MW. a) Vehicle for shifting/movement of spare/scrap /workmen etc in contractor scope . Hydra if required of assistance in work shall be provided by TPCIL. b) Erection of scaffold , for carrying out the job mentioned above is in contractor scope c) Works will be carried out round the clock d) After completion of work, daily job report with the details of work carried out and consolidation of spares and consumables issued by TPCIL is to be submitted. Final report with all the details of replacement, spares used, consumables used etc. shall be prepared & shared with TPCIL. e) Tools, tackles need to comply with statutory norms and should be submitted to TPCIL for inspection. TPCIL has the right to reject any tool if found unsafe f) All electric tools(hand tools , extension box ,welding machines etc ) will be submitted for inspection to TPCIL latest one day before work commencement g) All illumination lighting used shall be of 24V only h) Contractor shall be responsible for dismantling and assembly of equipment as a whole or any particular if any abnormalities are observed at the time of installation i) Contractor shall be responsible for attending/repair of any welding works found faulty at the time of quality inspection. j) Contractor shall be responsible for attending to any/all leakages identified at the time of air leak test. k) After completion of work, housekeeping of work site & equipment cleaning is prime responsibility of contractor. l) Contractor shall be responsible for any damage during the execution of work due to reasons attributable to them and the cost of damage shall be recovered on mutual agreement between TPCIL and contractor. m) Contractor shall provide a site safety plan before commencement of work to TPCIL for its approval. n) Contractor shall arrange for shifting of scrap material to marked areas after completion of work failing of which shall attract penalty. o) Contractor shall ensure that tools, machines, lighting arrangements, instruments and all accessories deployed by them is sufficient and shall ensure work is done round the clock

p) All the manpower and T&P should be fully mobilized before start of work to ensure full attendance of all workers on first day of start of work.

MINIMUM TOOLS LIST

 a) Spanners and sockets ,general hand tools (hammers ,hacksaw frame ,chisel ,punches ,tin cutters etc) b) 50T jack 1 nos 

c) Level gauge, filler gauge, Vernier, measuring tapes, straight edge, square level, dial gauge, water level. 

d) Chain pulley block 5T -2 nos, Chain Pulley 10T- 3Nos. 

e) Ratchet pulley 2 T -2 nos 

f) Associated slings and shackle UPTO 10 Tons 

g) Welding machine (3 phase) and accessories – 04 sets. h) Cutting set – 2 sets i) 24V transformer, handlamps j) Industrial socket extension boards – 3 nos k) Portable electrode oven -4 nos l) Electric hand tools – AG4 – 4 NOS , AG7 -2 Nos , drilling machine 2 nos m) Scaffolding pipes and clamps ,footboards  

MINIMUM CONSUMABLE LIST a) General consumable like cotton waster, banian cloth , marking cloth ,marker pens b) General purpose welding electrodes 6013 ,3.15 mm c) Gases for cutting set (only DA to be used ) d) Cutting and grinding wheels e) WD 40 spray and diesel for cleaning works .

PRICE BID 

 S.NO.    PARTICULARS              QTY      UNIT    RATE      AMOUNT 

 1 ROLLER EVAGINATION 

SYSTEM INSTALLATION 

& TESTING                                      1          LSM 

RESPONSIBILITY MATRIX:

S.NO Description      Responsibility        Remarks 

1.1 Detailed Man power deployment schedule Y

1.2 Arrangement of Manpower Y

1.3 Travel expenses for staff and workers Y

1.4 Accommodation and related facilities for manpower Y 

1.5 Local conveyance of staff and workers Y 

1.6 Drinking Water for manpower Y 

1.7 Canteen facility around the clock. Y 

1.8 Compliance with latest statutory norms and TPCIL safety policy Y

2        SITE SERVICES 

2.1 Required work permits Y

2.2 Daily work report Y

2.3 Provide available required drawings, specifications and OEM manuals Y 

2.4 Attending works as specified in scope Y

2.5 Power, Compressed Air in area of Work Y

2.6 Scaffolding material (pipes ,planks, clamps ) Y

2.7 Tools required for works as mentioned in contract Y 

2.8 Special T&P provided by OEM Y 

2.9 Loading & Unloading, Handling of Material site and Inland Transportation Y 

2.10 Inland Movement of Manpower Y

2.11 All maintenance Gases (Oxygen ,acetylene & Argon) required for maintenance works Y

2.12 Consumables ( marking cloth, cotton waste ,banian cloth ,grinding /cutting wheels, cleaning          diesel) Y  

2.13 Consumable for tools of cutting and welding (electrode general purpose only ) Y

2.14 Spares ,Special consumables, Welding Electrodes. Y

2.16 Housekeeping responsibility after completion of work Y

3               SAFETY 

3.1 Qualified safety Engineers/Supervisors Y

3.2 PPE for staff & workers Y

3.3 Safety nets wherever required Y

3.4 Regular tool box talks Y

3.5 Compliance with latest statutory norms and TPCIL safety policy Y