The Fertilisers And Chemicals Travancore Limited Tender

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.

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 new skirt board/ belt scraper as per the requirement with 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 new conveyor belt from the CD store / the 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 [ up to 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. 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/ workshop. 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 the available drawings/sample frames.

Servicing of Troughing & Return Idlers of All Sizes: 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.

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

Feed Conveyor Belt Replacement : The new conveyor belt from CD - store / old usable belt from the site shall be transported and unloaded at the required site. Decouple the drums from the connected parts and disassemble the sprocket, sensor, and other accessories from the conveyor. The drum with plummer block and bearings shall be dismantled as per the site requirement and taken to the Mechanical workshop. The damaged old belt shall be removed. The new belt shall be pulled in and placed properly to suit with site condition. The arrangements like idler/frame dismantling, wooden planks fixing, belt supporting, etc. shall be done for setting the conveyor belt in position. Removed idlers/frames shall be fixed back properly. The dismantled drums 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 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. The trial 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.