Copy of Relining Bp 2008-09 - Final

8/14/2019 Copy of Relining Bp 2008-09 - Final

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CELL RELINING MATERIAL PROCUREMENT COST PER POT FOR 2008-09 FOR VSS SMELTER 1

SL. NO CODE NO. ITEM UNIT

1 Carbon block MT 15.6 52900 825,240

2 Silicon Carbide Blocks MT 0.25 124000 31,000

3 Dia-thermic Bricks & Mortar MT 0.1 135000 13,500

4 Cold ramming mass MT 4.8 34000 163,200

5 13800747 Fireclay brick 230*115*40 Nos 500 22 11,000


7 13801000 Insulation Bricks 230*115*65 Nos 3600 21 75,240

8 61000562 MS Collector bar MT 10.99 36000 395,712

9 11205025 Plaster of paris MT 0.5 7700 3,850

10 13802028 Refractory Cement(Mccrete) MT 0.4 9537 3,815

11 60100921 Sodium silicate Grade 4 MT 0.15 12668 1,900

12 13802700 Fire clay mortor IS:8 MT 0.9 6600 5,940

13 13802200 Fire clay grit of IS:8 MT 2 6600 13,20014 60100425 Pig iron MT 2.5 21000 52,500

15 60100260 Ferro phosporous MT 0.1 27500 2,750

16 60100265 Ferro Silicon MT 0.06 50000 3,000

17 60100020 Asbestos powder MT 0.1 7150 715

18 61100050 Metal clads Nos 18 1760 31,680

SUB-TOTAL 1,759,642

1 U3000 MT 0.5 90000 45000

2 U6100 Aluminium HR plates for shunting MT 0.3 90000 27000

3 U3000 MT 0.2 90000 18000

4 10231 cast bar Mt 0.160 70000 11200

SUB-TOTAL 101,200

MECHANICAL SPARES1 12601500 MS plate 10mm MT 0.9 34668 31,201

2 12601530 MS plate 16mm MT 0.5 35310 17,655

3 12601550 MS plate 20 mm MT 0.1 34240 3,424

4 12603190 MS plate 3.15 MT 0.25 36380 9,095

5 12600297 MS Angle 150x90x12/11.2 MT 0.7 38000 26,600

6 12600045 MS angle 50x50x6 MT 0.05 30450 1,523

7 61004579 Al bronze Special nut Nos 6 7300 43,800

8 61100127 Fabricated corner Nos 4 1537 6,147

9 61000385 Shackle Insualtion bush Nos 8 248 1,980

10 61108205 Counter force Nos 6 13398 80,388

11 61004580 Counter force nut Nos 20 462 9,240

12 61006492 Counter force stud Nos 14 1657 23,192

13 61007774 MS washer for above Nos 20 61 1,210

14 10607479 Stud M20x110mm Nos 20 28 550

15 61108141 Jack foundation bush Nos 8 8 6216 61100295 Jack foundation plate MS Nos 4 345 1,382

17 61109645 Jack found. Ins. Plate Nos 4 185 739

18 10308120 Bearing 51220 Nos 5 5100 25,500

19 10300408 Bearing 7308 Nos 5 800 4,000

20 61100345 Stiffner plate Nos 82 175 14,342

21 61100128 Bend corner for anode casing Nos 4 1148 4,594

22 61007772 Jack foundation ins. washer Nos 10 25 253

23 61002168 GC hood 042 Nos 24 3630 87,120

24 61002110 GC hood 475 Nos 3 3850 11,550

25 61002112 GC hood 474 Nos 7 2200 15,400

PER POTCONS.

UNITRATE

IN RS.

TOTALPER

POT IN RS.

Aluminium flexibles for cathodeclad

Aluminium flexibbles for anoderiser


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26 61102111 GC hood 066 Nos 2.5 5500 13,750

27 61005260 GC Hood Pin Nos 24 165 3,960

28 61100280 GC Hood wedge nos 24 33 792

29 14607479 Wooden wedges Nos 8 61 484

30 14807499 wooden spacer nos 5 47 237

31 61006384 Screw for anode jack Nos 1.5 3300 4,950

32 13006452 Oil seal 40-x65x10 mm Nos 12 26 317

33 61108137 Shackle Insualtion Washer Nos 20 111 2,222

34 61000806 Cover through Screw Jack Nos 1 165 165

35 61000807 Blind Cover Nos 1 156 156

36 61000871 Cam for Screw Jack Nos 12 26 312

37 10109150 Cement Gasket Kg 0.5 275 138

38 13009855 Gaskets for burner small Nos 6 55 330

39 13009862 gasket for burner big Nos 6 41 246

40 10601010 Bolts 20 x 50 mm nos 16 55 880

41 10600510 Bolts 10 x 50 mm Nos 24 50 1,188

42 10600816 Nut bolt 16x 55 mm kg 2 32 64

43 10600814 Nut bolt 16x 70 mm kg 2 56 112

44 13002260 kg 2 24 48

45 61100095 Burner Body Nos 0.5 3284 1,642

46 61000912Nos 2

83 165

47 61000911 Cathode busing tie Nos 2 44 87

48 61605613 burner clamp Nos 2 75 149

49 61100286 pipe burner bend Nos 0.5 3658 1,829

50 61006620 casing screw nos 4 6050 24,200

51 12602260 hexagonal rod MT 0.25 35200 8,800

52 12602216 hexagonal rod MT 0.1 35200 3,520

53 13000690 Asbestos Rope 30mm Kg 0.03 132000 3,300

SUBTOTAL 494,988

CATHODE SHELL

50 61000916 Cathode shell - New Nos 0.6 845,000 507,000

51 61006622 Bottom plates Nos 0.4 275,000 110,000SUBTOTAL 617,000

TOTAL MATERIAL COST PER POT, Rs in lacs

2972830

CONTRACTS

1 Capital Relining of pots Nos 1 200000 200,000

2Nos 0.4

60,000 24,000

224,000

CAPITAL REPAIR COST PER POT, Rs in Lacs 3,196,830

(-) Scrap Sent to Foundry (Hr Plate and Flexibles) 0

Capital Repair Cost Per Pot 3,196,830No of Pots to be Relined 120

Total capital repair cost 383,619,595

Total Production (MT) 115,164

COST / MT (RS) 3,331ASSUMPTIONS:

1. Import under EPCG scheme.

2. Weight per Pot for Carbon Block 15.60 MT

3. Silicon Carbide Plate weight per pot taken as 0.25 MT, as per Simonsen Order

4. Weight per Pot for Diathermic Bricks taken as 0.100 MT, as per Clayburn Order.

10 mm asbestos sheet for busbar insulation

cathode busing clamp for 3bushes

Repair of Cathode shell and otherrepairs

TOTAL CONTRACT COST PER POT, Rs inlacs


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scrap to foundry (aluminum flexibles and busbar) 25,000

CAPITAL REPAIR COST PER POT, Rs in Lacs #REF!

Lacs #REF!


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SL. NO CODE NO. ITEM UNIT

1 Carbon block MT 15.6 71662 1,117,923


3 Dia-thermic Bricks & Mortar MT 0.1 135000 13,5004 Cold ramming mass MT 5.2 38720 201,344



7 13801000 Insulation Bricks 230*115*65 Nos 3800 21 79,420






13 13802200 Fire clay grit of IS:8 MT 2.4 6600 15,840

14 60100425 Pig iron MT 2.65 19800 52,470


16 60100265 Ferro Silicon MT 0.06 104500 6,270


18 61100050 Metal clads Nos 24 1760 42,240

SUB-TOTAL 2,139,773

1 U3000 MT 0.5 60000

2 U6100 Aluminium HR plates for shunting MT 0.48 57,000

3 U3000 MT 0.380 45600

4 10231 cast bar Mt 0.160 11,200

SUB-TOTAL 173,800

MECHANICAL SPARES

1 12601500 MS plate 10mm MT 0.9 35640 32,076

2 12601530 MS plate 16mm MT 1 36300 36,300

3 12601550 MS plate 20 mm MT 0.1 35200 3,520

4 12603190 MS plate 3.15 MT 0.25 37400 9,350

5 12600297 MS Angle 150x90x12/11.2 MT 0.7 31900 22,330

6 12600045 MS angle 50x50x6 MT 0.05 31900 1,595

7 61004579 Al bronze Special nut Nos 6 7150 42,900

8 61100127 Fabricated corner Nos 4 1537 6,147

9 61000385 Shackle Insualtion bush Nos 8 248 1,980

10 61108205 Counter force Nos 6 15950 95,700

11 61004580 Counter force nut Nos 20 508 10,164

12 61006492 Counter force stud Nos 14 1657 23,192

13 61007774 MS washer for above Nos 20 61 1,210

14 10607479 Stud M20x110mm Nos 20 28 550

15 61108141 Jack foundation bush Nos 8 8 62

16 61100295 Jack foundation plate MS Nos 4 345 1,38217 61109645 Jack found. Ins. Plate Nos 4 185 739

18 10308120 Bearing 51220 Nos 5 4253 21,263

19 10300408 Bearing 7308 Nos 5 1346 6,732

20 61100345 Stiffner plate Nos 82 175 14,342

21 61100128 Bend corner for anode casing Nos 4 1148 4,594

22 61007772 Jack foundation ins. washer Nos 10 25 253

23 61002168 GC hood 042 Nos 24 3630 87,120

PER POTCONS.

UNITRATEIN RS.

TOTALPER

POT IN RS.


Aluminium flexibbles for anoderiser


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24 61002110 GC hood 475 Nos 3 3850 11,550

25 61002112 GC hood 474 Nos 7 2200 15,400

26 61102111 GC hood 066 Nos 2.5 5500 13,750

27 61005260 GC Hood Pin Nos 24 165 3,960

28 61100280 GC Hood wedge nos 24 33 792



31 61006384 Screw for anode jack Nos 1.5 3300 4,95032 13006452 Oil seal 40-x65x10 mm Nos 12 26 317

33 61108137 Shackle Insualtion Washer Nos 20 111 2,222

34 61000806 Cover through Screw Jack Nos 1 165 165

35 61000807 Blind Cover Nos 1 156 156

36 61000871 Cam for Screw Jack Nos 12 28 330

37 10109150 Cement Gasket Kg 0.5 275 138

38 13009855 Gaskets for burner small Nos 6 55 330

39 13009862 gasket for burner big Nos 6 41 246

40 10601010 Bolts 20 x 50 mm nos 16 55 880

41 10600510 Bolts 10 x 50 mm Nos 24 50 1,188

42 10600816 Nut bolt 16x 55 mm kg 2 32 64

43 10600814 Nut bolt 16x 70 mm kg 2 56 112

44 13002260 kg 2 24 48

45 61100095 Burner Body Nos 0.5 3284 1,642

46 61000912 Nos 2 83 165

47 61000911 cathode busing tie Nos 2 44 87

48 61605613 burner clamp Nos 2 75 149

49 61100286 pipe burner bend Nos 0.5 3658 1,829

50 61006620 casing screw nos 4 6050 24,200

51 12602260 hexagonal rod MT 0.25 35200 8,800

52 12602216 hexagonal rod MT 0.1 35200 3,520

53 13000690 Asbestos Rope 30mm Kg 0.03 132000 3,300

SUBTOTAL 524,510

CATHODE SHELL

50 61000916 Cathode shell - New Nos 0.5 880,000 440,000

51 61006622 Bottom plates Nos 0.3 291,500 87,450SUBTOTAL 527,450

TOTAL MATERIAL COST PER POT, Rs in lacs 3365533

CONTRACTS

1 Capital Relining of pots Nos 225500 225,500

2Nos

40,000

TOTAL CONTRACT COST PER POT, Rs in lacs 265,500

CAPITAL REPAIR COST PER POT, Rs in Lacs 3,631,033


Capital Repair Cost Per Pot 3,606,033 36.06

No of Pots to be Relined 96Total capital repair cost 346,179,166







10 mm asbestos sheet for bus barinsulation

cathode busing clamp for 3 bushes



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Lacs #REF!


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CODE NO. ITEM UNIT

1 Carbon block MT 15.6 51500 803,400


3 Dia-thermic Bricks & Mortar MT 0.1 135000 13,500

4 Cold ramming mass MT 4.7 34000 159,800



713801000 Nos 3600 21 75,240






13 13802200 Fire clay grit of IS:8 MT 2.2 6600 14,520

14 60100425 Pig iron MT 2.5 21000 52,500


16 60100265 Ferro Silicon MT 0.06 50000 3,000


18 61100050 Metal clads Nos 18 1760 31,680

SUB-TOTAL 1,731,922

1 U3000 MT 0.5 90000 45000

2 U6100 Aluminium HR plates for shunting MT 0.35 90000 31500

3 U3000 MT 0.380 90000 34200

4 10231 cast bar Mt 0.160 70000 11200

SUB-TOTAL 121,900

MECHANICAL SPARES new code SAP Stock

1 12601500 MS plate 10mm MT 0.9 34668 31,201 10004681

2 12601530 MS plate 16mm MT 0.5 35310 17,655 10055826

3 12601550 MS plate 20 mm MT 0.1 34240 3,424 10055827

4 12603190 MS plate 3.15 MT 0.2 36380 7,276 10004686

MT 0.510007655

5 12600297 MS Angle 150x90x12/11.2 MT 0.5 38000 19,000 10035929

6 12600045 MS angle 50x50x6 MT 0.05 30450 1,523 10048251

7 61004579 Al bronze Special nut Nos 4 7300 29,200 10035934

8 61100127 Fabricated corner Nos 4 1537 6,147 10035916

9 61000385 Shackle Insualtion bush Nos 8 248 1,980 10035908

10 61108205 Counter force Nos 5.5 13398 73,689 10035918

11 61004580 Counter force nut Nos 16 462 7,392 1003593312 61006492 Counter force stud Nos 8 1657 13,253 10035939

13 61007774 MS washer for above Nos 16 61 968 10035917

14 10607479 Stud M20x110mm Nos 12 28 330 10007659

15 61108141 Jack foundation bush Nos 8 8 62 10035920

16 61100295 Jack foundation plate MS Nos 2 345 691 10035930

17 61109645 Jack found. Ins. Plate Nos 4 185 739 10035927

18 10308120 Bearing 51220 Nos 4 5100 20,400 10000754

19 10300408 Bearing 7308 Nos 4 800 3,200 10000753

20 61100345 Stiffner plate Nos 75 175 13,118 10035938B-607-M1-10-20816,ITEM:1

21 61100128 Bend corner for anode casing Nos 4 1148 4,594 10035906

22 61007772 Jack foundation ins. washer Nos 10 25 253 10035928

23 61002168 GC hood 042 ( long) Nos 15 3630 54,450 10035923

24 61002110 GC hood 475 ( plain corner) Nos 3 3850 11,550 10035925SM/M7/52/015/R6

25 61002112 GC hood 474 ( small) Nos 2 2200 4,400 10035926SM/M7/52/014/R6

SL.NO

PER POTCONS.

UNITRATE

IN RS.

TOTALPER

POT IN RS.

Mica innsulation Bricks230*115*65


Aluminium flexibles for anoderiser

ANGLEMTL,EQUAL,MS,150X150X12MM


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26 61000567 GC hood ( modified burner) Nos 2 5500 11,000 10045269

27 61005260 GC Hood Pin Nos 24 165 3,960 10035936SM/M7/52/022

28 61100280 GC Hood wedge nos 24 33 792 10035204



31 61006384 Screw for anode jack Nos 1 3300 3,300 10035937SM/M7/52/005

32 13006452 Oil seal 40-x65x10 mm Nos 6 26 158 10005715

33 61108137 Shackle Insualtion Washer Nos 10 111 1,111 10035909

34 61000806 Cover through Screw Jack Nos 1 165 165 10035919

35 61000807 Blind Cover Nos 1 156 156 10035907

36 61000871 Cam for Screw Jack Nos 6 26 156 10035910

37 10109150 Cement Gasket Kg 0.5 275 138 10035915

38 13009855 Gaskets for burner small Nos 6 55 330 10003596

39 13009862 gasket for burner big Nos 3 41 123 10003624

40 10601010 Bolts 20 x 50 mm nos 5 55 275 10001722

41 10600510 Bolts 10 x 50 mm Nos 5 50 248 10001706

42 10600816 Nut bolt 16x 55 mm kg 1 32 32 10065859

43 10600814 Nut bolt 16x 70 mm kg 2 56 112 10001889

44 13002260 kg 2 24 4810001570

45 61100095 Burner Body Nos 0.4 3284 1,313 10034361SM7-15-06-001R2

46 61000912Nos 2

83 16510034455DW:651845

47 61000911 Cathode busing tie Nos 2 44 87 10034438

48 61605613 burner clamp Nos 2 75 149 10031640

49 61100286 pipe burner bend Nos 0.5 3658 1,829 10034773SM-M7-52-031R3

50 61006620 casing screw nos 2 7000 14,000 10034927

51 12602260 hexagonal rod MT 0.25 35000 8,750

52 12602216 hexagonal rod MT 0.07 35000 2,450

53 13000690 Asbestos Rope 30mm MT 0.03 125000 3,125 40001251

SUBTOTAL 381,186

CATHODE SHELL54 61000916 Cathode shell - New Nos 0.6 854,000 512,400 10035914

55 61006622 Bottom plates Nos 0.4 280,000 112,000 10036017

SUBTOTAL 624,400

2859408

CONTRACTS

1 Capital Relining of pots Nos 1 225500 225,500

2Nos 0.4

60,000 24,000

249,500

3,108,908


Capital Repair Cost Per Pot 3,108,908No of Pots to be Relined 120

Total capital repair cost 373,068,986







EN 10035195

EN 10035196

EN 10034981 SM-M7-52-035

EN 10034746 SM-M7-52-027

10034802

10006339

10066995

11051

28.13

212

26.5

10 mm asbestos sheet for busbar insulation

cathode busing clamp for 3bushes

TOTAL MATERIAL COST PER POT, Rs in

lacs


TOTAL CONTRACT COST PER POT, Rs inlacs

CAPITAL REPAIR COST PER POT, Rs in

Lacs

WALKWAY (BIGSIZE),DW:SM-M7-52-053

WALKWAY(SMALLSIZE),DW:SM-M7-52-052

PLAT,S

HACKLEASSY&PIN,REAR,PN:079759

SHACKLE PINPT.NO.2933Z96/F0923615

rod,railing,mldsteel,dia25mm

columnfoundation stud

nylonsling

CASTBAR


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Lacs #REF!

Documents

Copy of Relining Bp 2008-09 - Final