Scope of Work for Replacement of motor at BF#5 Entire Complex

Ref Indent No:

Sl No Description of work UOM QTY

1 Replacement of Electrical motor Ton 80 SGE7215430200180
(HT Motors)
Replacement of Electrical motor From EA 20
below 9.3 KW
2 Replacement of Electrical motor From EA 20 SGE7215430200181
9.3 KW – 30 KW
3 Replacement of Electrical motor From EA 20 SGE7215430200098
37 KW
4 Replacement of Electrical motor From EA 16 SGE7215430200084
55 KW – 90 KW
5 Replacement of Electrical motor From EA 10 SGE7215430200082
110 KW – 160 KW
6 Replacement of Electrical motor From EA 10 SGE7215430200080
180 KW – 250 KW
7 Replacement of GCP Cooling tower gear box EA 2 SAC7215410400061
assembly
8 Replacement of SGP Cooling tower gear box EA 2
assembly
9 Replacement of TBS Cooling tower gear box EA 1 SAC7215410400054
assembly
10 Replacement of BF Cooling tower gear box EA 4 SAC7215410400055
assembly
11 Replacement of V-grove pulley size: 1000 mm EA 6 SPM7315000002068
12 Replacement of V-grove pulley size: 600- 700 EA 6 SPM7315000002066
mm
13 Replacement of V-grove pulley size: 400- 500 EA 16 SPM7315000002320
mm

A. DETAIL SCOPE FOR CONTRACTOR: (HT Motors Replacement)

 Shifting of HT Motors from store to work place.

 Receipt Of PTW Along with required certificates
 Ensure LOTO Of pump /Motor
 Shifting of all required tools and tackles.
 Dismantling of Machine Guarding
 Fixing of coupling to spare motor.
 All required tools and tackles.
 All moving equipments required for the job till, trailer & crane.
 De-couple the old motor.
 Erection of motor and alignment.
 Re fixing of Machine guarding
 Checking of rotation of motor.
 Coupling of new motor.
 Return of PTW & All certificates
 Trials of Pump & Motor
 If any abnormal in operation rectification of same in presence of JVML Engineer
 Shifting of old motor to designated place.
 Supervisor for the job
 Contractor has to supply sufficient gang to execute the work within the given time.
 All required arrangement for coupling removal should be made by contractor.
 Multi working groups for parallel jobs and number of activates and number of replacements at same time.
 Working elevation from – 8.0 Mts. to + 40.0 Mts (For both LT & HT Motors)

B. DETAIL SCOPE FOR CONTRACTOR: (LT Motors Replacement)

 Shifting of LT Motors from store to work place.

 Receipt Of PTW Along with required certificates
 Ensure LOTO Of pump /Motor
 Shifting of all required tools and tackles.
 Dismantling of Machine Guarding
 Fixing of coupling to spare motor.
 All required tools and tackles.
 All moving equipment’s required for the job till, trailer & crane.
 De-couple the old motor.
 Erection of motor and alignment.
 Re fixing of Machine guarding
 Checking of rotation of motor.
 Coupling of new motor.
 Return of PTW & All certificates
 Trials of Pump & Motor
 If any abnormal in operation rectification of same in presence of JVML Engineer
 Shifting of old motor to designated place.
 Supervisor for the job
 Contractor has to supply sufficient gang to execute the work within the given time.
 All required arrangement for coupling removal should be made by contractor.
 Multi working groups for parallel jobs and number of activates and number of replacements at same time.
 Working elevation from – 8.0 Mts. to + 40.0 Mts

C. DETAIL SCOPE FOR CONTRACTOR: (Cooling Tower Gear Box Replacement)

 Shifting of Gear Box along with Hub and blade assembly from store to work place.
 Receipt Of PTW Along with required certificates
 Ensure LOTO Of Motor
 Shifting of all required tools and tackles.
 Dismantling of Machine Guarding
 Fixing of coupling to spare gear box.
 All required tools and tackles.
 All moving equipment’s required for the job till, trailer & crane.
 De-couple the old gear box.
 Erection of gear box along with Hub and blade assembly and alignment.
 Re fixing of Machine guarding
 Checking of rotation of gear box.
 Coupling of new gear box.
 Return of PTW & All certificates
 Trials of gear box
 If any abnormal in operation rectification of same in presence of JVML Engineer
 Shifting of old gear box to designated place.
 Supervisor for the job
 Contractor has to supply sufficient gang to execute the work within the given time.
 All required arrangement for coupling removal should be made by contractor.
 Multi working groups for parallel jobs and number of activates and number of replacements at same time.
 Working elevation from 0.00 Mts. to + 16.00 Mts
D. V-Belt Pulley Replacement :

 Shifting of new V- Belt Pulley from store to work place.

 Receipt Of PTW Along with required certificates
 Ensure LOTO Of pump /Motor
 Shifting of all required tools and tackles.
 Dismantling of Machine Guarding
 Dismantling V-Belts
 Dismantling of Old Pulley.
 Fixing of New V-Belt Pulley
 Alignment of Pulley
 Re fixing of V-Belts
 Re fixing of Machine guarding
 Shifting of old pulley to designated place.
 Supervisor for the job
 Return of PTW & All certificates
 Trials of Pump & Motor
 If any abnormal in operation rectification of same in presence of JVML Engineer
 Contractor has to supply sufficient gang to execute the work within the given time.
 Multi working groups for parallel jobs and number of activates and number of replacements at same time.
 Working elevation from – 8.0 Ms.to + 2.0 .0 Ms.

E. JVML SCOPE:
 Required permit of work.
 Give clearance for de-coupling and coupling.
 Provide heavy crane (200t/90 t) if required.

F. Tools Required (Vendor Scope):

 Welding machine with welding cables, power cable, plug tops as in BF:5, welding machine check list, Consumables as required for
the job & welding face shield
 Gas cutting set with trolley, check list, spare gas cylinders as required for the job
 Standard tool box
 Fall arrester, safety belts and life line rope
 First aid kit
 Certified chain pulley blocks, wire rope slings & D-Shackles
 Hammering Ring & D Spanners of req. size for the job.
 Grinding & Buffing machines with power cable and plug top as in BF: 5
 All requited sizes hammering spanners for the job.
 Coupling pullers.
 Coupling fixtures.
 Alignments kit.

G. Safety:
 All JVML approved PPE’s should be provided to work force by contractor
 All workers should undergo training of JVML Corporate standards also all of them should have medical certificate. The same to
furnished if asked.
 Following standards are applicable to this job. PTW/WAH/LOTO/MATERIAL HANDLING, PPE’S, HEAVY LIFT & ESS safety standard’s
 For welding m/c, cutting set, grinding m/c and safety belts JVML standard checklist should be followed.

H. Up keeping:
 During job execution and after completion of the job, site should be maintained neat and clean.
 Scraps and grease should be cleaned immediately after job completion.
 All removed items should be shifted to designated place (Metallic /Non metallic).
 All required movable, lifting and erection, tools, equipment’s trailer, till and cranes required for the job.

I. JVML Scope:
 Work to permit (For each working group one dedicated contractor supervisor should be available)
  Corporate standard safety certificates (For each working group one dedicated contractor supervisor should be available) And
contractor has to full fill all the requirements which are required for each safety certificate.
 Spare motor and coupling
 All required fasteners, rustolene and cleaners.
 Crane, hydra and trailer for replacement and shifting

Annexure B- Scope of work preparation`:

Name/Designation of the requisitioned : Mr.Dharmaveera

Department/Location where work is to be done: BF:5
Work Description : Replacement of Electrical motor, Gear Box & V-Belt Pulleys
Area Awareness : BF:5 All area
Activities: Rigging & Alignment Hazard: Material may fall from height Risk Factor: Injury Control: Use only certified lifting tools
use Req PPEs
(List of Key Components of the Job)

Estimated Work Period: 8 to 20 Hrs.

Equipment (Hand tools): Standard tool box, Standard Rigging Tools, Hydraulic jack, puller alignment tools, cutting set, welding m/grinding
M/c Till, Trailer.

Specialist Equipment: Competent authority certification for Lifting machines tools & tackles and pressure vessels, Hydra (pick & carry
cranes), EOT cranes, Forklifts, and earth moving equipment’s (JCB, Pock lain). All buses, Utility vehicles, Jeeps and Cars should have seat
belts for all passengers including driver. RTO fitness certificate, Third party insurance coverage is required. Legal Licensing.

Estimated Utilization of Equipment’s (No. of Hours): Provide as per enclosed Annexure

Activity:
Man power Details: Provide as per enclosed Annexure: 01
Estimated Requirement of Consumables (Description/unit/ Qty) by user: Cutting set with Oxygen+LGP :01 No set , Welding
electrodes :0.5 to 1 Pack, Grinding wheel :01 Buffing wheel:01
Free Issue items/ Equipment to be provided by JVML (Description/Qty):

Special safety requirements

1 PTW Applicable
2 CSE Not Applicable

3 WAH Applicable
4 LOTO Applicable
5 MG Applicable
6 ESS Applicable
7 PPE’s Applicable
8 Conveyor Safety Applicable
9 Scaffolding Not Applicable
10 L&H Applicable
11 G&A Applicable
12 Chemical safety Not applicable
13 Fall of object Applicable
14 Fire Prevention Applicable
(Pertaining to the activities other than General): Special hydraulic puller or jack, jigs and fixtures to be made ready for removal of wear

rings and centering device.

Work to be done at: BF5 Entire Complex

Category of contractor required: Mechanical (Fabrication/Erection/Maintenance), Electrical, Civil (Painting/Masonry), Loading/Unloading:

Maintenance

General PPE's: Helmet Shoes Jackets Dust Mask Goggles Ear Plugs Gloves Apron Face

shield

Scope of Work for clear water & Slurry Water Pumps maintenance at BF#5 Entire Complex

Ref Indent No:

Sl No Description of work UOM QTY Item code

1 Clear water Pumps EA 6

2 Slurry Water Pumps EA 2

Contractor's Scope:

 Job is to be carried out with valid work permit & proper isolation to be ensured.
 Job is to be carried out as per the instructions of JSW Engineer instructions round the clock & completed
within specified time.
 Contractor has to carry out the jobs which is concern to main job
 Job is to be carried out with all safety PPEs and fire hydrant/ water hose to be ensured before starting the
work to prevent the fire incidents.
 One supervisor from contractor should present during carrying job being carried out.
 Lifting tools and tackles, accessories — Chain blocks, Slings, D -shackles should be certified by the
 competent persons before the use and will be in the scope of the contractor.
 All consumables, gases, electrodes, are under the scope of contractor
 Shifting of required material from CS/Sub stores to the work site will be under the scope of contractor
and should comply with materials handling corporate standard.
 Contractor should deploy Hydra /mobile equipment for replacement of pump/gear box, valve, pipe etc.
 After the completion of the job materials /scrap to be shifted to scrap yard & housekeeping to be done
as per JSW standards.
 Contractor has to ensure the safety of other related nearby equipment’s while working.
 All consumables like grinding wheel, DA and oxygen cylinders ,welding electrodes-E6013&E7018 will be in
the scope of the contractor.
 All tools and tackles like spanners, Welding machine, grinding machine, oven, cutting set etc. as per job
requirement will be in the scope of the contractor and should comply with JSW safety
standards/Check lists.

General Instructions for the Contractor

 Shifting of basic material or spares from either central store or sub stores to work site or fabrication yard
& fabricated part from yard to erection spot is under contract scope only.
 Contractor has to make his own arrangements for all the requirements of total transportation of his
workforce and others.
 Job has to be carried out as per JSW engineer's instructions only.
 Competent supervisor, continuous supervision, Skilled manpower is must.
 Skilled welder, standard welding procedure to adopt as per job demand & as per JSW engineer's
instructions. Quality welding to be ensured by conducting stage wise tests such as DP, UT test etc & in
case of any deviation same to be rectified. UT test facility will be provided by JSW.
 Sticking to time frame put by JSW is must.
 Day to Day house keeping should be ensured always & scrap should be shifted to designated place only.
 In case, any food or snacks, if issued during major repair works, contractor has to ensure proper disposal
of waste to designated place only.
 Work area should be maintained tidy, neat & clean always.
 Regular use of safety PPEs like safety helmet, safety shoes, safety goggle, ear plug, safety belt, safety
jacket, fall back arrestor, rope ladder or aluminum ladder etc must be ensured and PPEs under contractor
scope only. PPEs should be from standard manufacturer only and must be approved by JSW safety.
 Other safety equipment’s relevant to the job like blower mask, oxy-pack, CO monitor etc to be used.
These will be provided by JSW. But contractor has to ensure proper use of it & restoration of the same
after completion of the activity.
 Safety toolbox talk to be followed job wise & shift wise separately and same should be approved by
JSW engineer always.
 JSW Corporate Standards must be strictly ensured which are relevant to the job (Tick for Applicable
Standard)
Removal, dismantling, inspection, repair and rectification / replacement of Pumps.

1. Job to be carried out at blast furnace area during plant running/shut down only

2. During plant running particular equipment to be electrically isolated and suction and delivery
valves

be isolated with lockout system.

3. Job to be carried out after giving clearance from operation and

mechanical 4. Job to be carried out strictly as per instructions of

JSW engineer/SMP. 5. Disconnect the coupling from motor of the

pumps

6. Inspect the coupling under supervision of JSW engineer, if required the same to be rectified or

replaced with new one as per instructions

7. Dismantle the pump upper casing as per instructions

8. After dismantling the pumps, the spares of pumps to be cleaned thoroughly as per instructions of
JSW

engineer

9. Required cleaning agent is under scope of JSW

10. Inspect under supervision of JSW engineer and required repair and rectifications to be carried out
as

per instructions of JSW engineer

11. Inspection of gland ropes as per instructions of JSW engineer and if required the same to rectified
or

replaced as per instructions

12. Inspection of sleeves of pumps to be carried out as per instructions and under JSW engineer
supervision and if required the same to be rectified or replaced with new one as per

instructions of JSW engineer

13. Inspection of impeller of pumps to be carried out as per instructions, under JSW engineer
supervision

and if required the same to be rectified or replaced with new one as per instructions of JSW
engineer

14. Inspection of wear rings of the pumps to be carried out as per instructions, under JSW engineer
supervision and if required the same to be rectified or replaced with new one as per

instructions of JSW engineer

15. Inspection of bearings of the pumps to be carried out as per instructions and supervision of JSW

engineer and if required the same to be rectified or replaced with new one as per

instructions of JSW engineer .

16. Inspection of shaft of the pumps to be carried out as per instructions and supervision of JSW
engineer

and is required the same to be rectified or replaced with new one as per instructions of JSW
engineer
 17. Inspection of foundation bolts to be carried out if founds any abnormal the same to be rectified or

replaced with new one

18. Inspect the gasket and the same to be replaced with new one

19. Required oil seals to be replaced

20. Disconnect the suction and delivery lines as per instructions and the same to be re connected after

giving clearance

21. While carrying the above jobs if any machining to be done the material to be shifted to CRS for
repair

and rectification and the same to re shifted back to work place after completion and as per
instructions

22. Alignment of motor and pump to be carried out as per instructions

23. Alignment readings to be recorded and to be shown to JSW engineer

24. After giving clearance regarding alignment only further jobs to be processed

25. Required lubrication to be done to the pumps and spares as per instructions of JSW engineer

26. Photo to be taken during dismantling condition of the pump and after assembling and completion
of

the job and the same to be attached with bill

Removal, dismantling, inspection, repair and rectification / replacement of

cooling tower gear boxes

1. Job to be carried out at blast furnace area during shut down

2. Job to be carried out as per instructions of

JSW engineer

3. Job to be carried out at an elevation of + 10 to + 15 meters

4. Job to be started after giving clearance from operation, mechanical and electrical

5. Contractor has to make approach platform to work safely inside the cooling tower fan.

6. Remove the gear box with fan assembly.

7. Inspect the condition of fan blades and if any damages found , same to be replaced.

8. Required crane (Except Hydra) to carry out the job is under scope of JSW

9. Alignment to be carried out and readings should be recorded and should reach

limits as per

requirement

10. Required house keeping to be carried out and photo to be attached

PREVENTIVE MAINTENANCE OF PUMPS

1) Job to be started after giving clearance from operation, Electrical & mechanical department through proper PTW and
 LOTO only.

2) Pumps preventive maintenance to be done as per pumps check list & check list to be duly signed by contractor
supervisor.

3) Suction & Discharge valve to be closed with lock out & tag out system to be follow.

4) Removal of coupling guard of the pump.

5) Check the condition of the coupling & pin bush/spider.

6) Foundation bolts of motor/pumps tightness checking.

7) Check gland seal condition of both DE & NDE side. If gland leakage is heavy leakage replace packing.

8) Checking of gland hose condition & choking. If choke clear the jam & re-fix the hose.

9) Pump shaft freeness checking

10) Pump bearing lubrication to be done.

11) Checking pump to motor misalignment. If any misalignment inform the area incharge & align the motor, reading to
be

recorded before & after alignment.

12) Coupling gap to be maintained (Min. 3mm & Max. 8 mm).

13) Condition of the suction & delivery bellow, tie rods tightness to be checked.

14) Condition of the suction & delivery valves to be checked

15) If belt driven pump, check pulleys taper lock bush & pulley groove condition.

16) Check the taper lock bush fastners tightness

17) Checking belt condition.

18) Pump & Motor pulleys plumb reading to be taken.

19) IF Pump to motor mis-aligned, inform jsw engineer and re-align the motor.

20) Checking belt tightness. If slackness found tighten the belt.

21) After completion of the alignment clean the pump.

22) Housekeeping to be carried out after completion of the job.

 Replacement of parts on site wherever possible. Wherever the pump can be re-commissioned by
replacing the parts in site be done in position.
 Wherever the pump needs overhauling to re-commission the pump, the job shall be done in at
specified area or workshop.
 Shifting of pump to Workshop is under JVML scope. The pump will be submitted to the workshop
with a problem description.
 Inspection of pump & preparation of detailed jobs to be done for repairing of pumps and
refurbishment.
 Complete overhauling of the pump consisting of cleaning the parts in the workshop, strip down,
inspection of spares, replacement of the spares, and reassembly of the pump.
 All spares are JVML scope ,it may be OEM or others make.
 Supervision of installation, alignment, and Trial run at the final stage.
 To analyze the reason for repetitive/major failures and submission of observation report
 Submission of inspection report of all pumps on a daily basis.
 Submission of spare planning details every 6 Months.
 Scope of work does not include any Automation/Electrical work.

Maintenance
 A mechanical hoist or the like should be used when lifting parts weighing more than 30 kg. The
weights of the pump components are given in the spare parts list.
WARNING!

Before any work is started, follow the JVML Corporate safety standards motor must be disconnected
from the mains or the main Switch turned off and locked so that the pump cannot be started
inadvertently. It will sometimes be necessary to work with the pump in operation when greasing the
bearing and adjusting the shaft seal. When working in the vicinity of the freely rotating shaft, make
sure that all personal equipment is arranged so that it cannot fasten in the rotating parts. Work with
care and exercise good judgment.

Note: all pumps Inspection, maintenance periodic/schedule/break down & Shut down &
Repair/servicing as per OEM recommendations only.
Make of Pumps: KBL, Wilo, Metso & Weir Minerals