Inspection , Repair And Replacement Of Prayon Filter Trays And Channels In Pa Plant , Fact Cd ., AMBALAMEDU-Kerala

Inspection , Repair And Replacement Of Prayon Filter Trays And Channels In Pa Plant , Fact Cd . , Inspection , Repair And Replacement Of Prayon Filter Trays And Channels In Pa Plant , Fact Cd . , Fabrication Of Hollow Shafts Of Prayon Filter Trays : Collection Of Required Materials And Consumables From Store . Hollow Shafts Shall Be Fabricated Out Of Salvaged 200 Nb/ Sch 160 200 Nb Pipe/Sch 160 Ss 316L Pipe And End Flange Out Of 25 Mm Ms Plate . Transport The Fabricated Shafts And Flanges To Workshop For Machining And Collect Them Back After Machining And Transport To Work Site As Per Instructions From Engineer In Charge . , Encasing Of Prayon Filter Shaft ( Filter Hose Side ) :Make Required Arrangements For The Work . Remove The Existing Ms Encasing On The Hv9 Shaft By Grinding . Fabricate New Encasing Out Of 6Mm Ms Plate By Rolling To Required Profile . Encase The Shaft Area With New Encasing In Two Halves . Full Weld The Encasing On All Joint Areas . Suit The Bearing On The Bearing Area By Proper Grinding . Inspect The Flange For Any Repair . Damaged Flange Areas Shall Be Welded And Ground As Per Instructions . , Repair Works In Spare Filter Trays . Shift And Transport The Spare Filter Tray To Earmarked Area . Clean Thoroughly The Spare Filter Tray . Position The Filter Tray Properly And Suitably . Leak Test The Tray By Filling Water . All Arrangements For Leak Testing Including Fabrication And Providing End Dummies Shall Be Done By The Contractor . Inspect For Leaks . Also Inspect The Trays For Any Surface Cracks . Collect The Required Materials For Repair From Store And Transport To Work Site . Repair The Leaked And Cracked Areas By Proper Grinding The Crack/Leak Area And Repair Welding With Suitable Electrode . Suitable Pad Plate Is To Be Provided As Per Instructions . The Welding Area Shall Be Dp Tested And Inspected By Engineer In Charge . After The Repair Welding Is Successfully Completed , Leak Test The Tray Again . Once The Leak Test Is Successful Drain The Water And Transport The Tray To Earmarked Storage Area As Per Instructions From Engineer In Charge , The Tray Has To Be Neatly And Safely Stacked . The Leak Test For The Trays Has To Be Carried Out As Many Number Of Times Till The Test Results To No Leak . All Arrangements For Leak Test Will Be Under Contractors Scope . , Replacement Of Filter Tray End Hollow Shaft ( Cell Control Lever Side ) :Clean Thoroughly The Filter Tray . Shift And Transport The Filter Tray To The Earmarked Area . Assemble The Filter Tray On The Fixture And Perfectly . Provide Steady Pins For Firmness . Grind The Cladding On The Shaft . Dismantle / Cut The Existing End Shaft . Prepare The Edges With Proper Grinding . Assemble New Shaft , Properly Align The Shaft With The Filter Tray . Full Weld The Shaft With The Tray Using Suitable Electrode . Properly Grind The Weld Joint And Carry Out Dp Test . Any Flaw Detected Will Have To Be Reworked . Provide Stiffeners For The Weld Joint Area With The Tray As Required . After Complete Welding And Grinding Provide An Encasing Of Hv9 Material Covering The Weld Joint Area And On Hollow Shaft Upto The Bearing Area , And Full Weld On The Encasing Using Suitable Electrode As Per Instructions From Engineer In Charge . Once The Replacement Work Is Complete , Unmount The Tray From The Fixture And Transport The Tray To The Stacking Area As Per The Instructions From Engineer In Charge . Clear The Site And Transport The Scrap To Area Earmarked / Scrapyard . , Fabricate Filter Support Channel :Collect The Required Material From Store And Transport To Work Site . Take Measurement From Existing Filter Support Channel , Using Ms Ismc And Ms Plate As Per The Instructions From Engineer In Charge . All Joints Shall Be Full Welded . Pad Plates Shall Be Provided At Required Areas / Joints And Shall Be Full Welded As Per Instructions From Concerned Engineer . All Welding Areas Shall Be Properly Ground To Facilitate Rubber Lining . Once The Fabrication Is Complete Shift And Transport The Channels To Rubber Lining Area For Rubber Lining . After Completion Of Rubber Lining Transport The Support Channel To Stacking Area And Safety Stack The Channels As Per Instructions . , Replacement Of Prayon Filter Support Channel :Transport The Spare Support Channel To Prayon Filter Site . Collect The Required Tools / Tackles / Consumables From Store / Work Shop . After Getting Process Clearance And Positioning Of Filter Trays , Cut And Dismantle The Existing Support Channel . Grind And Finish The Welding Areas On The Filter Frame . Erect The New Support Channel To The Required Position . Properly Position The Channel And Correct The Alignment Of The Channel With The Frame . Properly / Full Weld The Joint Areas With The Channel And Filter Frame . Take Trail Run And Confirm The Position Of Channel Is Correct With The Position Of The Tray And There Is No Entangling Of Filter Tray With The Channel . Any Rework Arising Out Of This I . E . , Repositioning And Re Welding Of Channels Etc . Shall Be Done As Per Instructions From Concerned Engineer . After Successful Trial Run , Clear The Site And Transport The Scrap To Area Earmarked / Scrapyard . , Replacement Of Prayon Filter Tray :After Getting Process Clearance Dismantle The Splash Guards , Cell Control Lever , Filter Hose Etc . Of The Tray To Be Replaced . Dismantle The Ci Bearings Of The Tray . Shift And Transport The Tray To The Repair Bay . Repair The Tray For The Damage / Cracks Etc . Set New Ci Bearings On The Filter Shafts . Ensure The Bearings Suits The Filter Shafts ( Bearings Have Only Design Clearance With Shaft ) Under The Supervision Of Concerned Engineer . Shift And Transport The Repaired / Spare Tray Assembly To The Site And Erect The Filter Tray To Position . Position The Ci Bearings On The Frame And Properly Tighten The Base Bolts And Cover Bolts . Mount The Control Level Assembly , Filter Hose And Splash Guards Etc . Take Trial Run And Ensure The Tray Doesnt Entangle With Other Trays / Filter Support Channel . Any Rework Arising Out Of This Shall Be Done By The Contractor . After Successful Trial Run Clear The Site And Transport The Scrap To Earmarked Area / Scrap Yard As Per Instructions .

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