FABRICATION OF A NEW INDUCED DRAUGHT FAN DUCTING KILN 2

Transcription

1 FABRICATION OF A NEW INDUCED DRAUGHT FAN DUCTING KILN 2 SITE INFORMATION The tenderer should, in his own interest, visit the site and familiarize with the site conditions before tendering. For any clarification, tenderer may discuss with the customer. CONFORMITY WITH STATUTORY ACTS, RULES, STANDARDS AND CODES i) All components shall conform to the relevant standard specifications, whatever existing, amended to date. ii) All electrical works shall be carried out in accordance with the provisions of Kenya Electricity rules. SAFETY MEASURES AND REQUIREMENTS i) A thorough site risk assessment to be done before commencement of work. ii) All personnel involved in the job to be safety inducted for familiarization with the scope of work and the risks involved. iii) A risk assessment board to be availed on site furnished with the permit to work, hot work permits and job procedure. iv) Ensure all electrical connections have been isolated and a Lock out, Try out, Tag out procedure have been followed before taking over the plant for the job. v) A person in charge of safety to be identified and be known to all the personnel during working hours. vi) A first aid kit to be availed on site at all times and a shift first aider identified. vii) Suitable Fire extinguishers to be availed on site at all times during the operation. viii) All drop zones and operation areas to be barricaded using red/white barrier tape to restrict entry to persons not inducted for and/or not involved in the job. ix) Scaffolds to be inspected after erecting and after any modifications before personnel are allowed to use them. Only qualified scaffolders to erect scaffold x) All oxy-acetylene sets to be inspected and tested for leakages before use and hoses to be clear of falling hot material, sharp edges and dropping debris. xi) All personnel shall wear the mandatory PPE at all times and ensure use of other relevant PPE depending on the nature of work and condition of the work site. xii) Ensure sufficient lighting at the site. xiii) Housekeeping to be done at every stage of work and thoroughly at every close of shift. LABOUR REGULATIONS i) The contractor shall abide by all TCML laws and regulations. WORKS TO BE ARRANGED BY THE TCML

2 Unless otherwise specified in the tender documents, the following works shall be arranged by the owner. i) Space for accommodating all the equipment and components involved in the work. ii) Erection of the scaffolds at the site. iii) Provide all technical drawings required. iv) Provide all equipments, consumable items and materials required. v) Supervision of the work. WORKS TO BE ARRANGED BY THE CONTRACTOR Unless otherwise mentioned in the tender documents, the following works shall be done by the contractor and therefore, their cost shall be deemed to be included in their tendered cost-whether specifically indicated in the schedule of work or not: - i) Fabrication of the new ducting. ii) Tear down of the existing ducting. iii) Installation of the new ducting. iv) Paint of all exposed metal surfaces of equipments and components with appropriate colour. v) Disposing of the waste material to the scrap yard. TOOLS REQUIRED i) Two sets of combination spanners ranging from No. 17 to 32 ii) 4 Nos. 2 Kg. engineering hammers. iii) 2 Nos. long claw bars. iv) 2 Nos. 3tonne by 5 meter chain blocks v) 1 No. 5tonne by 5 meter chain block. vi) 2 Nos. 5tonne single roller pulleys. vii) 4 Nos. soft slings size 3 tonnes x 3 meters. viii) 4 Nos. soft slings size 5 tonne x 3 meters. ix) 4 Nos. D shackles 5 tonne capacity. x) 2 Nos. DC welding machines 400amps and above complete with welding and earthling cables 70 cubic mm and above, each cable 15meters long or more, fitted with welding holders and earth clamps of 600 amps or above. xi) 1 Nos. 9 grinder complete with its safety guards. xii) 2 Nos. complete oxy-acetylene cutting sets, each with 15 meter long or more hoses, double diaphragm oxygen and acetylene regulators, heavy duty cutting torches and non-return valves for fitting at the regulator side. xiii) 3 Nos. single phase extension cables each 15 meters long or more.

3 CONSUMABLES REQUIRED i) 4 Nos. size 1/8 Acetylene Cutting nozzles of good quality preferably Affrox from BOC. ii) 5 Nos. size 1/16 Acetylene Cutting nozzles of good quality preferably Affrox. iii) 10Kgs. 3.25mm Low hydrogen Welding electrodes. iv) 10Kgs. 4.00mm Low hydrogen Welding electrodes. v) 10Kgs. 3.25mm mild steel Welding electrodes. vi) 5Kgs. 4.00mm mild steel Welding electrodes. vii) 5 pcs. 9 cutting discs. viii) 3 Nos. full acetylene cylinders of size 6.8 cubic meters or more. ix) 8 Nos. full oxygen cylinders of size 8.3 cubic meters or more. x) 5 Nos. wire brushes. EQUIPMENT i) A low loader and prime mover or tractor with open body trailer for moving new parts closer to the loading area, with carrying capacity of at least 5 tonnes. ii) 5 tonne folk lift

4 JOB PLAN. Pre installation preparations. i) Mechanical layouts indicated on the drawings are diagrammatical. Co-ordination (final) shall be required with other trades prior to installation. Install all works as shown on the drawings, unless prevented by project conditions. ii) All dimensions in the brackets to be checked prior installation of equipment. iii) Move the new parts close to the site to reduce time taken during installation. iv) Erection of the scaffolds at the site. v) All dimensions in the brackets to be checked prior installation of equipment. FABRICATION. i) The Contractor shall verify all measurements and shall notify the owner of any difficulty in carrying out his work before fabrication. ii) All duct work shall be of high quality approved galvanized sheet steel guaranteed not to Crack or peel on bending or fabrication of ducts. iii) All ducts shall be fabricated and installed in workman like manner, generally conforming to relevant codes. Round exposed ducts shall be die formed for achieving perfect circle configuration. iv) Ducts shall be fabricated as per details shown on drawings. All ducts shall be rigid and shall be adequately supported and braced where required. v) Duct dimensions shown in drawings are overall sheet metal dimensions inclusive of the acoustic lining where required. vi) Ducts shall be straight and smooth on the inside with neatly finished joints. All joints shall be made air tight. vii) Ducts shall be fabricated as per details shown on the drawings. All ducts shall be rigid and adequately supported. INSTALLATION viii) During installation, the Contractor shall temporarily close duct openings with sheet metal covers to prevent debris-entering ducts and to maintain opening straight and square, as per direction of the owner. ix) Modify the scaffold at every stage of the job to suit. x) Arrange piping installations adjacent to units, xi) The ductwork shall be varied in shape and position to fit actual conditions at the site. xii) Great care should be taken to ensure that the ductwork does not extend outside and beyond height limits as noted on the drawings. xiii) Connect piping to all equipment with flanges enabling easy removal of the coil. xiv) Make final duct connections with flexible connections. xv) Rubber gasket 3 mm thick shall be used between duct flanges and between duct

5 xvi) Ducts shall be acoustically lined and thermally insulated fabric to withstand 200deg c. xvii) Change in dimensions and shape of ducts shall be gradual to avoid turbulence. xviii) Sheet metal connections shall be as shown in the drawings or as directed by owner. xix) Change in dimensions and shape of ducts shall be gradual. Air turns shall be installed in all vanes arranged to permit the air to make the turn without appreciable turbulence. xx) Accessories such as damper blades are to be of materials of appropriate thickness and the finish similar to the adjacent ducting. xxi) Thorough housekeeping at the end of every shift. xxii) Test and commission. NOTES All welds to be continuous fillet U.O.S. All Bolts to be graded 8.8 to SABS 136. All sharp edges to be removed and deburr hole. All external steelwork to be painted as per TCML specs. All loose flanges to be primed only and all surfaces to be abrasive blast cleaned to SA 2.5. All flange joints to be supplied with 6mm ROPE GASKET. Ducting to be cladded to 50mm THICK MIN USING MINERAL WOOL DENSITY 100KG/M 3 Refer to : 1. MAGADI SODA-KENYA EXHAUST DUCTING DETAIL DRAWING No A MAGADI SODA-KENYA CYCLONE OUTLET DUCTING DETAIL DRAWING No A