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SUPPLY & INSTALLATION OF VOLATILE CONDENSABLE MATERIALS (VCM) TEST SYSTEM.

ENVIRONMENTAL TEST FACILITIES (ETF – II)

U.R. RAO SATELLITE CENTRE BENGALURU – 560 017.

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INDEX

Ref. No.

Description Page No.

1.0 Scope of Contract 3

1.1 Heritage 3

1.2 Introduction 3

1.3 General Requirements 6

2.0 Vacuum Chamber 7

3.0 Vacuum Pumping System 10

4.0 VCM Test Setup 13

5.0 Thermal System 14

6.0 Instrumentation & Control System 15

7.0 Source of supplies for Critical items 24

8.0 Criteria for system acceptance 25

9.0 Supply of Spares 25

10.0 Training 26

11.0 Warranty 26

12.0 Delivery Schedule 26

13.0 List of Deliverables 26

14.0 Legend 28

LIST OF FIGURES

Fig. No.

Description Page No.

1. Over view of VCM test system 29

2. Base Adapter 30

3. Top Chamber 31

4. Vacuum Schematic 32

5. VCM Test setup 33

6. Hot Bar 34

7. Cover Plate 35

8. Hot Bar support bracket 36

9. Cold Bar Assembly 37

10. Cold Bar 38

11. Cold Bar support bracket (Right) 39

12. Cold Bar support bracket ( Left) 40

13. Separator Plate 41

14. Collector Plate 42

15. Configuration of VCM test setup 43

16. Annexure –I [Compliance statement] 44-47

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1.0 SCOPE OF CONTRACT This document provides the detailed specification of VCM test system to be established at URSC, Bengaluru, on turn-key basis for testing & qualification of materials used in spacecraft. Specification for various sub-systems of VCM test system such as Vacuum chamber, Vacuum pumping system, Thermal system, VCM test setup, Instrumentation and Control system are included in the document. The scope of work for this project includes;

i. “Total Design, Fabrication, Assembly, Supply, Transportation to site, Installation, Testing and Commissioning of complete VCM Test System”.

1.1 HERITAGE

The vendor should have executed at least one similar contract / project in the field of Thermal vacuum chambers/space simulation chambers / VCM Chambers. The vendor shall submit the complete details of such projects executed during last 5 years along with customer reference and contact details as well as total time taken in executing the same after award of such execution contract. Heritage in supply of thermal vacuum chambers is of prime importance and bids without heritage shall not be considered. The Vendor should provide the name and contact details such as Postal address, telephone number, email address etc., where the similar system was supplied.

1.2 INTRODUCTION

The proposed Volatile Condensable Materials (VCM) test system is used for screening Polymeric / Organic / In-Organic materials used on Spacecraft and shall comply with ASTM -E-595 standards. The typical VCM test system requirement and specification details are sub-divided in the following FIVE major categories:

1.2.1 Vacuum Chamber: a) Cylindrical Chamber shell. b) Ports and Flanges. c) View port. d) Chamber support structure. e) Hoist.

1.2.2 Vacuum Pumping system: a) Roots pumping Station (Combination of Roots pump with Rotary vane pump) b) Cryo pump. c) Vacuum valves. d) Vacuum plumb lines and fittings.

1.2.3 VCM Test setup:

a) Hot Bar b) Cold Bar

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c) Inlet / Outlet manifolds & feedthroughs.

1.2.4 Thermal System: a) Heating-Using Electrical Heaters with associated feedthroughs. b) Cooling- Using Refrigerated Circulator with associated feedthroughs.

1.2.5 Instrumentation & Control: a) 19” Instrumentation Rack b) Electrical power distribution, MCB, Switches, Indicators c) Mimic diagram d) Vacuum gauges & Controllers e) PID Temperature Controllers. f) PLC. g) Data Acquisition System. h) Chamber Illumination

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Major Constituents of VCM Test System

VCM TEST

SYSTEM

Vacuum

Chamber

VCM Test

Setup Instrumentation

& Control

Thermal

System

Vacuum

Pumping

System

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1.3 GENERAL REQUIREMENTS:

The Vendor shall be fully responsible from design stage to final commissioning stage and to prove the system design adequacy, as needed for the entire project. The Vendor shall specify various activities and milestone up to completion of this activity (VIZ configuration, design, fabrication, testing, qualification etc.) The proposed configuration shall ensure highest level of reliable functioning combined with ease of operation and maintenance. Vendor shall adhere to the following guidelines:

1.3.1 Selection of mechanical / electrical / electronic equipment / components shall be of high quality, established generic reliability and long standing in market.

1.3.2 Part supply will not be acceptable.

1.3.3 Judicious incorporation of full or partial redundancy as required while maintaining its cost effectiveness.

1.3.4 Modular design concept allowing future expansion and augmentation.

1.3.5 High quality workmanship using well trained, qualified, certified personnel and meticulously supervised manpower.

1.3.6 Use of standard / recommended fabrication and assembly procedures and construction practices.

1.3.7 Use of calibrated gauges, sensors, transducers and instruments.

1.3.8 The system as well as all other subsystems shall be rated for minimum of 50 hours of continuous operation and the same shall be demonstrated. During these tests all subsystems are expected to be exercised to meet the ASTM E-595 standards.

1.3.9 Fabrication, Transportation and Installation schemes shall be compatible with conditions of local roads and utilities available at the site.

1.3.10 The chamber shall be fail-safe and hazard free during interruption of power or compressed air.

Vendor shall provide the following without fail along with quote:

1.3.11 Overall time schedule in the form of Bar Chart / GANTT/ CPM/PERT network diagram, refer delivery schedule u /s 12.0.

1.3.12 Completely filled Compliance Statement, format as in Annexure – I.

1.3.13 Supporting documents such as Product catalog / data sheet of all instrument / equipment.

1.3.14 P & I diagram of Electrical & Control system.

1.3.15 Heritage in supply of Thermal Vacuum chamber.

1.3.16 Compliance to General & Commercial terms of contract.

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1.4 SCOPE OF SUPPLIES FROM URSC / ISRO

1.4.1 Building for the System with general utilities.

1.4.2 Compressed air at maximum pressure of 6 bar(g) is available at URSC/ISRO for pneumatic actuation. Vendor shall carry out necessary distribution, plumbing work & regulation for the same as needed by the system.

1.4.3 Required electrical power as already available with URSC/ISRO at pre-decided location (terminated through a switch in a nearby LT Power Panel). Vendor shall carry out further electrical power distribution and control for the total system with aesthetic cable tray. Design of the system by the vendor shall be in-line with the above mentioned resources provided by URSC / ISRO.

2.0 VACUUM CHAMBER

SPECIFICATIONS, GUIDE LINES AND PERFORMANCE REQUIREMENTS

2.1 Dimensions of Vacuum Chamber:

Vacuum Chamber comprises of two parts i.e. i) Base Adapter which is rigidly mounted to base support structure ii) Top Chamber, which moves vertically up / down by using motorized Hoist.

2.1.1 Base Adapter (Ref. Fig. 2)

Inner Diameter: 650 mm Qty: 01 No Height: (clear inner height) 180mm

2.1.2 Top Chamber (Ref. Fig. 3)

Inner Diameter: 650 mm Qty: 01No Height: (clear height excluding depth of

torrispherical dished end at top) 450mm

2.2 Configuration:

2.2.1 Chamber longitudinal axis – Vertical.

2.2.2 Vacuum chamber is mounted on rigid support structure fitted with wheels and height adjustable jacks, support structure shall rest on suitable vibramounts at base for vibration isolation.

2.2.3 The chamber is rigidly mounted on support structure which is 1.2m (appx.) from floor level (Ref. Fig.1).

2.3 Hoist:

Top chamber is connected to a motorized hoist to enable smooth vertical movement for loading and unloading of test samples. Hoist shall be of electromechanical -Screw and Nut type. Hoist shall have controlled movement with limit switches at both extreme ends. Hoist shall be designed with a FOS of ≥ 4 with rigid mounting at convenient location preferably between port No. 3 & 4 of Base adapter, refer Fig. 2.

2.4 Guide Rod: A suitable guide rod as shown in fig. 1, is mounted on Base adapter for guiding movement of Top chamber while opening & closing.

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2.5 Material of Construction:

2.5.1 Chamber body /stiffeners/reinforcements/ports and parts exposed to vacuum: AISI-SS-304L or its equivalent.

2.5.2 Chamber external supports & attachments: SS or MS Powder coated / Painted with Polyurethane paint.

2.6 Design guide lines:

2.6.1 The chamber shall be designed as per unfired pressure vessel code ASME – Section VIII, DIV- 1, for external pressure vessels or IS 2825 or BS 5500 or equivalent. Vendor shall specify relevant code proposed to be followed otherwise.

2.6.2 Number of welding joints shall be kept minimum using largest available plates.

2.6.3 All welding inside the chamber shall be continuous and staggered outside as per industry practices and applicable standards.

2.6.4 No crossing of welding and no entrapped volumes inside welds are permitted.

2.6.5 Root pass welding must be by Argon arc / TIG / Helium arc method.

2.7 Instruction for Fabrication of Chamber:

2.7.1 Bright polished mirror finish / electro polish inside the chamber with surface emissivity of ≤ 0.15 except at weld joints. Weld joints should be buffed to best possible finish.

2.7.2 All finished components shall be protected from scratches and contaminants.

2.7.3 Chamber welds shall be radiographed as per applicable design codes.

2.7.4 All ‘O’ rings are of Viton & shall be of suitable hardness. All ‘O’ rings should be baked to 80°C preferably in vacuum prior to use. All ‘O’ rings must be inspected for defects, cracks, etc., prior to use.

2.7.5 All ‘O’ ring grooves shall be of trapezoidal or dove tail and mating surface shall have surface finish better than 1.6-micron Ra value, scratch free and comply individual leak rate requirements.

2.7.6 The vacuum chamber shall be assembled on trial basis prior to transport to site to verify the vacuum requirements.

2.7.7 All user ports shall be closed using SS Blank off flanges along with applicable Viton ‘O’ ring and SS fasteners / clamps.

2.7.8 Adequate & appropriate safety practices shall be followed during fabrication, welding, lifting, movements, erection, etc. till commissioning of the complete system.

2.7.9 The chamber and vacuum system configuration design details shall be presented during Detailed Design Review (DDR) for approval by URSC/ISRO.

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2.8 Inspection & Quality Control requirements:

2.8.1 All the materials shall be tested and certified for chemical composition and strength values prior to use.

2.8.2 Strict quality control and third party inspection shall be implemented.

2.8.3 Nondestructive testing like DPT (Dye penetration test), Ultrasonic, Radiography shall be carried out as per applicable standards.

2.8.4 A comprehensive inspection and quality control scheme shall be prepared in respect of each of the systems/subsystems. All the test certificates, inspection reports, calibration certificates, etc. shall be produced as per sec 13.2 & 13.3.

2.8.5 CHAMBER PORTS DETAILS (TENTATIVE)

Note: All port sizes, location on chamber, hoist location as shown in drawings are tentative.

Final size and location shall be frozen during DDR. Port size for vacuum pumping systems can

be suitably chosen to match with the pump / valve interface flange.

2.9 View Port:

Size Material & Specification Qty Location

DN 160 ISO-F Quartz/ Fused silica / or suitable 01 No. Top Chamber

RefFig. No.

LOCATION Port No. PORT SIZE PURPOSE

2

Base Adapter

(DN 650 ISO-K)

1 DN 200 ISO or suitable for High Vacuum Gate Valve

High Vacuum Gate Valve for Cryo pump.

2 DN 25 KF/40 KF or suitable Hand valve & Piezo gauge

3 DN 16 KF/40 KF or suitable Chamber vent

4 DN 40 KF Cooling media - IN

5 DN 40 KF Cooling media - OUT

6 DN 16 KF/40 KF or suitable Pirani gauge for Chamber

7 DN 25 KF/40 KF or suitable Compact Full Range Gauge

8 DN 40 KF Chamber overpressure relief valve

9 DN 40 KF or suitable Electrical feedthrough

10 DN 40 KF or suitable Electrical feedthrough

11 DN 63 ISO-K Chamber Roughing port

12 DN 40 KF or suitable Power feedthrough

13 DN 40 KF or suitable Power feedthrough

3 Top Chamber

14 DN 40 KF Illumination lamp

15 DN 40 KF (Middle) User

16 DN 160 ISO (Middle) View port

17. DN 650 ISO-K To suite with Base Adapter

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3.0 VACUUM PUMPING SYSTEM

Configuration of vacuum pumping system is shown in Fig. 4 Roots station (combination of roots pump and backed by a rotary vane vacuum pump) shall be used for roughing the Chamber and Cryo pump. Pumping speed of Roots station shall be ≥ 250 CMH. Roots Pumping Station: Qty: 01 No. 3.1 Technical Specification of Roots Pumping Station: The Roots Pumping Station comprises of a

Roots pump backed by a Rotary Vane Pump with the following specification; Roots Pump:

Sl. No.

Description Specification Needed

3.1.1 Nominal Pumping Speed ≥ 250 m3 /hr

3.1.2 Ultimate total pressure (without gas ballast)

≤ 1 x 10-3 mbar

3.1.3 Cooling Air cooled

3.1.4 Inlet Flange ISO 63 or larger.

3.1.5 Outlet connection ≥ DN 40 KF

3.1.6 Drive Hydro kinematic drive / Magnetic / or suitable.

3.1.7 Pump down Roots pump shall be able to start from atmosphere & continuously operate at all pressures below atmosphere when backed with a suitable fore pump.

Rotary Vane Pump:

Sl. No.

Description Specification Needed

3.1.8 Pump Type: Direct Drive, Oil base Rotary Vane Pump

3.1.9 No. of stages Two

3.1.10 Inlet Port DN 40 KF or higher

3.1.11 Nominal Pumping Speed ≥ 30m3 /hr.

3.1.12 Ultimate Total Pressure (without gas ballast)

≤ 3 x 10-3 mbar

3.1.13 Ultimate Total Pressure with gas ballast ≤ 7 x 10-3 mbar

3.1.14 Water Vapour tolerance 7 to 50 mbar

3.1.15 Water Vapour capacity ≥ 200 g /hr

3.1.16 Anti suck-back Shall be provided

3.1.17 Exhaust Filter ( Oil Mist Eliminator) Shall be provided 3.1.18 Power Supply 50 Hz, 220V AC, Single Phase or

50 Hz, 415 V AC Three Phase

Cryo Pump, Qty: 01 No. 3.2 Gaseous Helium cooled (G-M cycle based) cryogenic pump (non-LN2 cooled type) with

regeneration system. Cryopump shall be connected to base adapter with a high vacuum gate valve. The specification of Cryo pump is as follows:

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Sl. No.

Description Specification

3.2.1 Mouth Flange Size: ≥ DN 200 ISO-K or suitable

3.2.2 Pumping speed a. Water

≥ 4000 l /s

b. Hydrogen ≥ 2500 l/s

c. Argon ≥ 1200 l /s

d. Nitrogen / Air ≥ 1800 l /s (N2) OR ≥ 1500 l/s (Air)

3.2.3 Capacity a. Argon

≥ 700 bar-l

b. Hydrogen ≥ 10 bar-l in 10-6 mbar range

3.2.4 Crossover ≤ 210 mbar-l

3.2.5 Cold down time ≤ 110 min.

3.2.6 Regeneration type Suitable heater shall be provided.

3.2.7 Compressor Air cooled

3.2.8 Supply and Return Hoses Supply and Return Hoses of suitable size and length shall be supplied.

3.2.9 Leak Tightness: After assembly, there shall be no detectable leak when measured using Sniffer mode of MSLD.

3.3 VACUUM VALVES:

Roughing station & Cryopump shall be equipped with Electro-Pneumatically operated, normally closed (NC- type) high vacuum isolation valves. The valves shall have high conductance for molecular flow.

3.3.1 Technical Specification of High Vacuum Gate Valve: A high vacuum gate valve of space saving type shall be provided between cryopump and base adapter with the following specification:

Sl. No. Description Specification Needed

3.3.1.1 Size DN 200 ISO- F or higher, suitable to cryo pump

3.3.1.2. Body Material Stainless steel / Aluminium

3.3.1.3. Mechanism Stainless steel

3.3.1.4. Differential pressure on the gate Between 1.1 to 1.6 bar in either direction.

3.3.1.5. Leak Rate less than or equal to 2x10-9 mbar-l/sec (He)

3.3.1.6. Pressure range Atmosphere to ≤ 2 x 10-8 mbar.

3.3.1.7. Actuator Electro Pneumatic

3.3.1.8. Actuator seal Bellow sealed

3.3.1.9. Seal : Bonnet & Gate Viton

3.3.1.10. Solenoid coil rating 220V AC 50 Hz / 24V DC

3.3.1.11. Type Double acting with position indicator

3.3.1.12. Mounting Position Any

3.3.1.13. Compressed Air pressure Between 4 to 8.5 bar

3.3.2 Details of other vacuum valves as shown in Vacuum schematic, Fig.4 are as follows:

Sl. No. Valve size Type of actuation Location

3.3.2.1. DN 63 ISO Electro pneumatically operated On Base adapter for Chamber roughing.

3.3.2.2. DN 40 KF Electro pneumatically operated Fore line of cryo pump

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3.3.2.3. DN10/16 KF Electrically operated. Chamber Vent

3.3.2.4. DN25/40 KF Manually operated Piezo gauge isolation

3.3.3 Specification of vacuum valves as mentioned in 3.3.2.1 to 3.3.2.4 are as follows:

Sl. No. Description Specification Needed

3.3.3.1 Body Material Aluminium / SS

3.3.3.2 Gate seal Viton

3.3.3.3 Actuator seal Bellows sealed

3.3.3.4 Leak Rate - Body Less than or equal to 1x10-9 mbar lit./ sec (He.)

3.3.3.5 Leak Rate - Seat Less than or equal to 1x10-8 mbar lit./ sec (He.)

3.4 Operational Vacuum with VCM Test setup at ambient temperature: Vacuum chamber with

VCM test setup (at ambient temperature) shall be evacuated at the following rate:

3.4.1 Atmosphere to 1 x 10-2 mbar in less than or equal to 20 minutes using Roots station. 3.4.2 Atmosphere to ≤ 5 x 10-5 mbar in less than or equal to 30 minutes using Cryo pump

(excluding cryo pump cool down time).

Vendor has the liberty to suitably locate & position Cryo pump, ports & valves to meet the vacuum requirement as described u/s 3.1, 3.2, 3.3, 3.4 & overall requirement, subjected to the approval of URSC/ ISRO. Details provided in figures are only indicative. 3.5 Gas loads for Vacuum System sizing:

Active & Passive loads from chamber and its elements as applicable shall be computed by the

Vendor in selection of Rough and High vacuum pumps, valves, plum lines and fittings.

3.6 Vacuum System Requirement:

3.6.1 All components, bellows and plumb lines used shall be of AISI-304L (or equivalent grade).

3.6.2 The system should meet pump down criteria as defined under section 3.4.

3.7 Leak tightness: All components, piping, welds, all joints, valves, bellows, ‘O’ ring seals, etc.

shall have an individual leak rate of less than 1 x10-8 mbar-l/s (He).

3.8 Venting and Purging System:

3.8.1 Piezo electric gauge shall be used for monitoring chamber pressure during controlled venting of chamber from high vacuum to any settable pressure in the range of 1 mbar to 999 mbar (user selectable). Vent valve shall close after reaching the set pressure.

3.8.2 Chamber shall have provision for venting by both Air and GN2 with proper interconnections & independent isolation valves.

3.8.3 Suitable filters shall be provided for both Air and GN2 for dust free venting by Air / GN2. 3.8.4 Chamber should be protected from over-pressurization by providing suitable relief valve

during venting / purging by GN2. 3.8.5 Necessary safety interlocks in vacuum system, thermal system, top chamber movement, etc.

must be provided.

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4.0 VCM TEST SETUP

VCM Test Setup shall be fabricated to comply requirements as per ASTM E -595 standard and installed inside the chamber, as shown in Fig 5 & 15. The VCM test setup comprises of the following:

Sl. No. Description Qty.

4.1 Hot bar 04 No’s.

4.2 Cold bar 02 No’s.

4.3 Separator plate 04 No’s.

4.4 Collector plate 32 No’s.

4.5 Cover Plate 32 No’s.

4.6 Base plate 01 No’s.

4.1 Hot bar:

There shall be totally four number of Hot bars as shown in Fig 6, made of electrolytic grade pure copper and surface treated by nickel and chrome plated. Two copper bars shall be assembled to a stainless steel Support bracket as shown in Fig 8 with suitable thermal insulator such as PTFE / Fibreglass and firmly mounted on base plate.

Each copper bar is heated and maintained precisely at 125 °C ± 0.8°C by electrical heaters rigidly mounted on both sides of bar for uniform heating. Heaters shall be compatible for high vacuum application and shall not generate particulate or molecular contamination inside chamber. Each bar shall have 8 No’s. of specimen mounting ports. All the four hot bars shall be simultaneously heated from ambient to 125 °C ± 0.8°C within 30 min.

Each Hot bar shall contain 03 No’s. of temperature sensors (PT-100) for temperature monitoring.

4. 2 Cold bar:

The overall assembled view of Cold bars is shown in Fig 9. There are two number of cold bars as shown in Fig 10 made of electrolytic grade pure copper and surface treated by electroless nickel and chrome plated. Each cold bar is assembled with stainless steel Support brackets (Right & Left) as shown in Fig 11 & 12 respectively which are mounted on adjustable guides such that the spacing between hot and cold bar can be precisely maintained during test and retracted by more than or equal to 50 mm during mounting and demounting of collector plates before and after test. Each cold bar shall accommodate 16 No’s of Collector plates as shown in Fig 14. Each cold bar is vacuum brazed with copper tubes throughout the length to enable uniform cooling by circulating water which is pumped by a refrigerated circulator and maintained at 25°C ± 0.8°C when hot bar is at 125 °C.

Each cold bar shall contain 02 No’s of temperature sensors (PT-100) for monitoring uniformity.

4. 3 Separator plate:

Each cold bar is covered with separator plates made of Aluminium as shown in Fig 13. There are totally 04 No’s of separator plates in VCM test setup.

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4.4 Collector plate:

Collector plates are made of Aluminium as shown in Fig 14 and assembled on Cold bar. There are totally 32 No’s of collector plates in VCM test setup.

4.5 Cover Plate:

Each specimen mounting port on Hot bar is covered with a Cover plate. Cover plates are made of electrolytic grade pure copper and surface treated by electroless nickel and chrome plated as shown in Fig 7. There are totally 32 No’s of cover plates in VCM test setup. The cover plates shall be suitably mounted to enable easy fixing and removal for loading & unloading of test specimens. Vendor shall come up with suitable design and present during DDR for approval by URSC.

4.6 Base Plate with legs:

A stainless steel base plate with four height adjustable legs as shown in Fig 5 houses the entire VCM test setup.

4.7 Alignment of VCM Test setup:

During assembly, Vendor shall ensure that the axis of specimen mounting port in hot bar, hole axis in Separator plate and Hole axis in Cold bar are aligned, ref. fig 15. A clear and uniform gap of 3.8 ± 0.05mm shall exist between Separator plate and Hot bar after assembly.

5.0 THERMAL SYSTEM

5.1 HEATING SYSTEM

There shall be 04 No’s. Hot bars in the VCM test setup. Heaters are rigidly mounted on two sides of each hot bar and heated to 125 °C ± 0.8°C and maintained for 24 hrs during regular use. After completion of every test, decontamination of VCM test setup is carried out by heating the Hot bars to +150 °C ± 3°C in 10−6 mbar range for a minimum of 5 Hrs. Design shall ensure effective heat transfer from heater to hot bar. The capacity of each heater shall be around 250 watts or more.

Heaters shall be compatible for high vacuum application and shall not generate particulate or molecular contamination inside chamber. All the four hot bars are simultaneously heated from ambient to 125 °C ± 0.8°C within 30 min. Each hot bar is controlled by individual PID Controller.

Provision shall also exist to independently heat the hot bar to any intermediate temperatures between 25°C to 125°C and maintained for required duration.

For qualification and acceptance of the system, the hot bars are heated to 125 °C ± 0.8°C and maintained for 50 hrs.

5.2 COOLING SYSTEM

Refrigerated circulator: A refrigerated circulator is used to circulate distilled water in cold bars to maintain 25°C ± 0.8°C throughout the test. Inlet & Outlet manifolds are placed inside the vacuum chamber and connected with individual flexible lines (SS bellows) with detachable fittings to each cold bar as shown in Fig 5. The refrigerated circulator is positioned on a stand of suitable height to

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enable easy circulation with minimal pressure drop and thermal losses. The lines outside the chamber shall be suitably insulated with aesthetic finish.

5.3 Technical Specification of Refrigerated Circulator: Qty.: 01 No.

Sl. No. Description Specification needed

5.3.1. Working Temperature Range ≤ -20 deg. C to ≥ +200 deg. C

5.3.2. Temperature Indication on Display in deg. C LED /LCD

5.3.3. Temperature stability ≤ ± 0.02 deg. C

5.3.4. Temperature measurement sensor RTD or suitable

5.3.5.

Cooling Power @ a. 0 deg. C

≥ 200watts

b. – 20 deg. C ≥ 50watts

5.3.6.

Circulation pump a. Discharge Pressure

≥ 0.7 bar

b. Discharge Flow rate ≥ 26 l/min.

c. Suction Pressure ≥ 0.4 bar

d. Suction Flow rate ≥ 22 l/min.

5.3.7. Filling volume 4 to 5 litters

5.3.8. Power 230V AC, 50 Hz

5.3.9. Excess temperature Protection Shall be provided.

5.3.10. Safety Class Protection Class III, DIN 12876 or equivalent.

5.3.11. Alarm Indication for low liquid level and high / low temperature

Shall be provided.

6. INSTRUMENTATION & CONTROL SYSTEM

6.1 A suitable control and instrumentation system shall be accomplished with the following functions:

6.1.1 Complete system shall have all necessary safety interlocks for human safety and equipment safety for failure free operations during the test.

6.1.2 System shall have necessary protection against single phase, reverse phasing, power failures,

under / over voltages, jamming of pumps etc.,

6.1.3 Mimic panel indicating real time ON/OFF status of all the instrument / equipment.

6.1.4 PLC is used to carry out the main control functions such as sequencing the operation of Roots pumping station (Roots pump with RVP), Cryo pump and regeneration system, Vacuum valves, Chamber venting, Hoist movement, etc. Power to all the elements shall be individually controlled by providing MCB, fuses and individual switches.

6.1.5 Pirani gauges shall be used for measurement of rough vacuum in fore line of Cryo pump and

Chamber, Compact Full Range Gauge for reading high vacuum in chamber. 6.1.6 Venting of chamber shall be carried out as per section 3.8.

6.1.7 Paperless Recorder shall be used and interfaced to acquire chamber pressure data from

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Compact Full Range gauge mounted on chamber, temperature data from RTD mounted on the hot & cold bars, Provision for secure & reliable data storage, provision for future expansion shall exist for additional hardware channels and display.

6.1.8 Standalone Alarm / Hooter / Buzzer shall be provided to alert operator if the temperature/ chamber pressure varies beyond set limits.

6.1.9 There shall be four Hot bars and each Hot bar is controlled by an independent PID based

temperature controller. The control system shall also be capable to heat and maintain different temperature in different Hot bars from +25°C to +150°C. Heating system shall also include necessary power supplies to heaters for controlled heating & achieving better temperature uniformity.

6.1.10 Motorized Hoist equipped relevant safety features with controls shall be used for opening

and closing the top lid of chamber.

6.1.11 Illumination lamp shall be mounted inside the Top chamber for viewing during test. 6.2 Instrumentation and Control system shall have the following hardware:

Sl. No Item description Quantity (No.)

6.2.1 Programmable Logic Controller (includes I/O modules, power supply, wiring accessories etc.) ( Ref. 6.3) As per requirement

6.2.2 Electrical switch gear (Fuses, MCBs, MCCBs, Contactors, OLRs, relays, connectors, etc.) ( Ref. 6.4)

As per requirement

6.2.3

Stand-alone instrumentation (includes gauge heads, sensor cables etc.)

a) Pirani gauges (Sensor) b) Display & control unit. (Ref. 6.5.1)

2 No’s 1 No.

c) Compact full range vacuum gauge with independent Display & Control unit. ( Ref. 6.5.2)

1 set.

d) Digital Absolute pressure gauge (Piezo type). ( Ref. 6.5.3) 1 set.

6.2.4. Data Logging: a. Paperless Recorder (Ref. 6.6.1)

1 No.

b. Alarm / Hooter ( Ref 6.6.2) 1 set.

c. Temperature sensors, PT – 100 with cable & connectors (Ref 6.6.3)

16 No’s

6.2.5. PID based Temperature Controllers (Ref. 6.7)

4 No’s

6.2.6 Electrical Heaters - (Ref. 6.8) As per Requirement

6 6.2.7 Feedthroughs a. Electrical / Signal feedthrough ( Ref. 6.9.1)

1 No.

b. Power feedthrough (Ref. 6.9.2)

As per Requirement

6.2.8 Instrumentation rack

01 No.

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a. Instrumentation racks is of standard 19” size with service lamp & cooling fan.

b. Mimic panel indicating real time ON/OFF status of all the instrument/equipment.

c. The Control & Instrumentation system shall be housed in standard 19” instrumentation rack with all gauge controllers, PLC, PID controllers, DAS, switches, indicators, etc. along with LCD / LED displays are ergonomically designed and integrated into a console so that the system can be operated and maintained conveniently.

As per requirement

6.2.9 Illumination Lamp with Power supply – (Ref. 6.10) 1 set.

6.3 Programmable Logic Controller

The PLC shall be optimized for high speed bit command execution and high speed word command

execution with suitable scan time. PLC shall be designed to provide simple solutions for

automation tasks such as logic control. The PLC system layout shall allow placing of controller in

the vacuum chamber main console while the input/output (I/O) interfaces may be conveniently

located either in the main console or near respective equipment for minimized wire runs and

simplified start-ups and maintenance.

The PLC which is housed in the main system console with suitable interface, shall carryout the

main control functions such as sequencing the operation of Vacuum system such as Roots

Pumping station, cryogenic pumps and their regeneration system, vacuum valves, vent valve &

hoist control. PLC to accomplish the tasks of loading, editing of the logic programs, force-ON

functions, etc.

The Broad specification of PLC is as below (the vendor may supply the hardware with advanced / better features based on the need and availability):

Sl. No.

Specification Qty.

6.3.1 Programmable Logic Controller with following features: 01 No.

6.3.1.1 Input / Output Channels: As per our requirement + 20% spare

6.3.1.2 The number & type of I/O modules are chosen as to suite the voltage levels required to drive the starters, Contactors and relays of various equipment.

6.3.1.3 The PLC processor shall be among the latest with suitable processing speed and functional capabilities.

6.3.1.4 The PLC processor Memory shall be chosen suitably to accommodate the logic programmes and have some extra capacity to take care of future expansion of the control logic programmes.

18

6.4 Electrical switch gear / power panels 6.4.1 All the electrical switchgear shall be of reputed make such as L&T, Siemens,

Schneider, Havells, etc. and must conform to national (IS) or international (CE, UL etc.) standards.

6.4.2 All the electrical switch gear like MCB’s, OLR’s, contactors, single phasing preventers, motor starters, timers, SSR, etc. shall be mounted on an insulated sheet and fitted vertically for convenience of maintenance.

6.4.3 The electrical switchgear shall be hardwired through the I/O modules of the PLC to the electrical loads using industry standard codes and practices.

6.4.4 All the wire terminations both power and control shall be connected to screw terminals (Elmax type) so as to facilitate modular installation, quick connection/disconnection and easy trouble shooting and repair.

6.4.5 The wire terminals shall be identified with numbered ferrules and properly crimped with appropriate lugs and colour codes shall be used wherever applicable.

6.4.6 The power and control wires are properly routed in PVC channels inside the panel.

6.4.7 The cables must confirm to relevant Indian standard/ international standard specifications.

6.4.8 All the electrical switchgear shall be of reputed make such as L&T, Siemens, Schneider, Havells, etc. and must confirm to national and international standards.

6.4.9 The electrical switchgear shall be hardwired through the I/O modules of the PLC to the electrical loads using industry standard codes and practices.

6.4.10 Cables/wires used shall be of copper, ISI certified, FRLS type and from reputed brands.

6.5 Standalone instrumentation: 6.5.1 Pirani Gauge with Display Unit:

Pirani Gauge Head : 02 Nos. Display & Control Unit : 01 No.

6.5.1.1.

Pirani Gauge Head Measurement Range

1000 to ≤ 5e -4 mbar

6.5.1.2. Gauge type Pirani

6.5.1.3. Accuracy : 0.002 to 20 mbar ≤ + / - 10 %

6.5.1.4. Repeatability : 0.002 to 10 mbar ≤ + / - 2 %

6.5.1.5. Body material SS

6.5.1.6. Filament Tungsten / Nickel

19

6.5.1.7 End Connection DN 16 KF

6.5.1.8 Over Pressure rating 4 bar

6.5.1.9 Sensor Cable length 5 m or suitable

6.5.1.10. Display Unit No. of Channels

02 No.

6.5.1.11. Display LCD / 4 digit 7 segment LED

6.5.1.12. Unit of Measurement (selectable) mbar, Torr, Pascal

6.5.1.13. Display Measurement Range 1000 to ≤ 5 e-4 mbar

6.5.1.14. Power 230V AC 50 Hz

6.5.1.15. Set Point Potential free changeover contact, 2 No.

6.5.2 Technical Specification of Compact Full Range vacuum gauge: Qty: 01 set

6.5.2.1

Gauge Head (Sensor) Type Combined Pirani + Cold cathode (inverted magnetron) gauge head

6.5.2.2 Connection flange DN 25 / 40 KF

6.5.2.3 Measurement Range 1000 to 5 x 10-9 mbar

6.5.2.4 Accuracy (10-8 to 100 mbar) ≤ ± 30%

6.5.2.5 Reproducibility (10-8 to 100 mbar) ≤ ± 5%

6.5.2.6 Output signal 0 to 10 V DC

6.5.2.7 Output signal sensor error < 0.5V

6.5.2.8 Operating temperature +5°C to +55°C

6.5.2.9 Filament Molybdenum for Cold cathode sensor and Tungsten for Pirani.

6.5.2.10 Leak rate ≤ 1 x 10-8 mbar l/sec

6.5.2.11 Bake out temperature +150°C without electronics

6.5.2.12. Max. Pressure exposed 10 bar

6.5.2.13 Flange material Stainless steel

6.5.2.14 Seal FPM / Viton

6.5.2.15 LED Indication for cold cathode YES

6.5.2.16

Sensor Cable Sensor Cable length

6 meter or suitable

6.5.2.17

Display and Control Unit No. of Channel

01 No.

6.5.2.18 Measurement range 1000 mbar to 5 x 10-9 mbar

6.5.2.19 Power Supply Single Phase, 230V AC 50 Hz

6.5.2.20 Interface RS 232 C or suitable

6.5.2.21 Measurement signal output 0 to 10V DC

6.5.2.22 Set Point Potential free changeover contact, 2 No.

6.5.2.23. Switching function relays Rating 60V DC , 30 watts (ohmic)

6.5.2.24. Measurement Unit (selectable) mbar / Torr / Pascal

6.5.3 Technical Specification of Digital Absolute Pressure Gauge (Piezo type): Qty: 01 set Display Unit:

6.5.3.1 Range 1 – 2000 mbar absolute.

20

6.5.3.2 Display ≥ 3 ½ digit, LCD/ LED display

6.5.3.3 Resolution 1 mbar

6.5.3.4 Sampling rate ≥ 3 samples /sec

6.5.3.5. Power Supply 230V AC, 50Hz

Sensor:

6.5.3.6 Type Piezo type

6.5.3.7 Pressure range 1 – 2000 mbar absolute

6.5.3.8 Accuracy ≤ ± 1 % of FS

6.5.3.9 Sensor material Ceramic / Metal

6.5.3.10 Seal material Viton

6.5.3.11 Operating temperature 10°C. to 50°C.

6.5.3.12 Sensor cable of suitable length connecting Sensor with Indicator.

6.6 Data logging: Chamber parameters such as chamber vacuum and temperatures are logged using Data logger / Paperless Recorder. The Data logger / Paperless Recorder shall have the following features/capabilities: a. Acquisition, measurement, logging, monitoring & recording / storage of the temperature

data from Hot & Cold bars in the system (16 channels).

b. Acquisition, measurement, logging and monitoring of the vacuum level in the chamber using Compact Full Range Gauge. The gauge analog outputs are suitably interfaced to the Paperless Recorder for display and storage.

c. There shall be a minimum of 20 channels (16 No. for temperature + 1 No. for chamber Pressure + remaining spare channels).

6.6.1 Specifications of Data logger / Paperless Recorder:

Qty: 01 No.

Sl No. Description Specification

6.6.1.1 No. of channels ≥ 20 channels, expandable to ≥ 24 channels.

6.6.1.2 Display ≥12.1” TFT colour, Touch screen.

6.6.1.3 Display Resolution ≥ 1024 × ≥ 768 pixel / ≥ 800 × ≥ 600 dots

6.6.1.4 Input Type Universal Input

6.6.1.5 Display resolution ≤ 0.1°C

6.6.1.6 Sampling rate ≤ 125 ms.

6.6.1.7 Internal Memory (RAM) ≥ 96 MB.

6.6.1.8 Provision for External Storage

a. Compact Flash / memory card b. USB Pen drive

6.6.1.9 Data Storage capacity a. Memory card: ≥ 08 GB with card reader.

b. USB Port: ≥ 08 GB

Location No. of Pt -100 Total No. of Pt-100

Hot Bar 03 No’s on each hot bar 12 No’s

Cold Bar 02 No’s on each cold bar 04 No’s

Total: 16 No’s (excluding spares)

21

6.6.1.10 Interface RS 232 / Ethernet or equivalent. Suitable interface cable

shall be provided.

6.6.1.11 Software To read the data in PC.

6.6.1.12 Display type User Selectable – Trend, Bar, Digital, Combination

display

6.6.1.13. High / Low Temperature Indication

By Alarm / blinking / flashing of colour.

6.6.1.14 Protection Class Front panel: IP 65 or better.

Housing & Terminals: IP 20 or better.

6.6.1.15 Math. function Shall be provided

6.6.1.16 Operating Temperature 10 to 50 deg C.

6.6.1.17 Standard Industry standard to meet CE/UL/ISI.

6.6.1.18 Calibration

All channels shall be calibrated for temperature from +150°C to 0°C as per below table. Calibration certificate with NABL traceability shall be provided.

6.6.1.19 Power Supply 220 V AC, 50Hz.

6.6.1.20 Operation manual in English language

Shall be supplied along with the instrument.

Calibration: All 20 channels of temperature sensors shall be Calibrated as per below table.

Temperature in deg.C

Ch.1 Ch.2 Ch.3 Ch.4 …………………Up to channel Ch.20

+150

+100

+50

0

6.6.2 Alarm / Hooter with tower lamp:

An Alarm / Hooter with tower lamp is provided to draw attention of operator for over / under temperature of Hot bars / Cold bars and increase in chamber pressure from set values.

6.6.3 Temperature Sensor: Qty: 16 No. (excluding spares) Calibrated three wire PT-100 temperature sensor of tolerance Class A as per IEC 60751 / Grade A, as per ASTM E 1137 or equivalent standard of suitable size, rugged, compatible for high vacuum application and easily replaceable type.

6.7 PID based Temperature controller:

Each Hot Bar temperature is controlled by dedicated temperature controller which can be programmed in PID mode by the operator. Specifications of PID based Temperature controller:

Qty: 04 No.

22

Sl. No. Description Specification needed

6.7.1 Input Type Universal input

6.7.2. Process input range Ambient to + 200 deg. C or wider

6.7.3. Accuracy ≤ ± 0.25% of Full scale ± 1 Digit

6.7.4. Sample Rate ≥ 4 Hz ( ≤ 250ms)

6.7.5. Resolution 0.1 deg. C

6.7.6. Display (LED/LCD) PV, SV

6.7.7. Zero offset User adjustable over full range

6.7.8. Outputs Op1 : pulsed 10-20 V DC for driving SSR (Heating)

Op2: Relay output (230v / 2A rating) Alarm: Absolute high/low, Deviation high/low

6.7.9. Status display Sensor break / Open / Short

6.7.10. Set point limit High and Low limit setting provision

6.7.11. Limiting the output power

Provision for variable output power to the process (0-100%)

6.7.12. Size 1/4 DIN (96mm X 96mm)

6.7.13. Power requirements 230V AC, 50 Hz

6.7.14. Display Dual display for both SV/ PV

6.7.15. Front Panel Push buttons for programming

6.8 Electrical Heaters

Qty: For Heating 4 No. of Hot Bars (excluding spares)

6.8.1 Electrical heaters are suitably selected to meet requirement as described in sec. 5.1.

6.8.2 Good thermal contact shall be ensured between heaters and hot bar for efficient and uniform heating.

6.8.3 Heaters shall be of easily replaceable type in case of fault.

6.9 Feedthroughs:

6.9.1 Technical specification for Electrical / Signal feedthrough Quantity : 01 Nos.

Sl No

Parameter Specification

6.9.1.1 Type Sealed wire harness feed through assembly for high vacuum systems. Feedthrough assembly along with tagged harness on either side.

6.9.1.2 Number of contacts/leads 50 (minimum)

6.9.1.3 Wire conductor material Silver plated copper (multi strand)

6.9.1.4 Conductor size 20 AWG

6.9.1.5 Voltage rating 600 volts

6.9.1.6 Wire length (each side) As required

6.9.1.7 Wire insulation Teflon

6.9.1.8 Housing type Miniature Circular or suitable

6.9.1.9 Housing material Stainless steel

6.9.1.10 Housing diameter 45 mm (maximum) or suitable

6.9.1.11 Mating flange cut-out 35 mm (Maximum) or suitable

23

6.9.1.12 Mating flange thickness Feed through should be able to accommodate flange thickness.

6.9.1.13 'O' ring material Viton

6.9.1.14 Leak rate ≤ 1X10 -7 std cc/ sec

6.9.1.15 Insulation resistance 5000 MΩ (minimum) at 500 volts

6.9.1.16 Operating temperature - 40°C to +100°C

6.9.1.17. Feed through must be Cadmium free

6.9.1.18 Compatible for high vacuum environment of 1x10-6mbar

6.9.2 Power feedthrough

Vendor shall select a suitable hermetically sealed Power feedthrough for heating 04 No. of hot bars. These feedthroughs are assembled on suitable size flanges and fitted in the ports. The specification of feedthroughs & mounting will be reviewed during DDR.

The feedthrough shall meet the following requirement:

Sl No Description Specification Needed

6.9.2.1 'O' ring material Viton

6.9.2.2 Leak rate Less than or equal to 1X10 -7 std cc/ sec

6.9.2.3 Feed through must be Cadmium free

6.9.2.4 Compatible for high vacuum environment of less than or equal to 1x10-6 mbar

6.10 Illumination Lamp Inside Vacuum Chamber

Chamber shall be illuminated with lamp for viewing inside the chamber during progress of VCM test. The illumination system shall be compatible for high vacuum and temperatures as seen from VCM test setup.

6.10.1 Lamp fixing: Lamp shall be fixed inside chamber with suitable feedthrough & wire connections (16 AWG PTFE wire or suitable).

6.10.2 Suitable lamp power supply shall be provided with switching control on the panel.

General Requirements of Instrumentation & Control System:

6.11.1 Required Accessories like sensor / signal connectors, connecting / extension/ sensor cables, etc. should be suitably provided.

6.11.2 Operation Manual of all instruments / equipment in English language shall be provided.

6.11.3 All the instruments shall be configured by the vendor as per the user requirement before trial test and acceptance.

6.11.4 Test / Calibration certificate shall be provided.

6.11.5 The detailed design of the instrumentation and control system along with the specifications of all the equipment, quantity, make, model etc. shall be provided.

6.11.6 The grounding scheme shall consist of two earths (less than 0.5 ohm for instrumentation and less than 1 ohm for chamber ground).

24

6.11.7 The whole system shall be designed for easy maintainability, approachability for operation, good aesthetic finish.

6.11.8 Electrical power and control cabling shall be done through proper routing with proper identification for easy maintenance and fault identification.

6.11.9 P & I diagram of all electrical & control system shall be provided along with quote.

6.11.10 The Instrument / Equipment specification mentioned for Instrumentation & Control system are only typical and the vendor can offer items that have better features / capabilities as an alternative by presenting the merits of such an alternative, subjected to approval of URSC / ISRO.

7. SOURCE OF SUPPLIES FOR CRITICAL ITEMS

LISIT OF RENOWNED BRANDS FOR CRITICAL ITEMS

Sl. No. Components Manufacturer

7.1 Roots Pumping Station Pfeiffer / Edwards / Leybold

7.2 Cryopump CTI/ HSR Balzers

7.3 Vacuum valves VAT / Pfeiffer / GNB / MDC / Kurt J. Lesker.

7.4 A) Vacuum gauges & Controllers B) Absolute Digital pressure gauge (piezo type)

Pfeiffer/ Inficon / MKS Pfeiffer/ Inficon / MKS/ Leybold / Brooks / IRA,

7.5 Feedthroughs Douglas engineering / Deutsch / Pfeiffer/ Plug In

7.6 View port (vacuum windows)

Huntington / MDC / VG / Allectra / Nor-Cal/ Vacom-Vacuum / equivalent reputed brands.

7.7 Illumination lamp (vacuum compatible)

Osram /Philips or renowned international brands.

7.8. Other accessories like flanges, pipe, etc.

From ISI certified renowned brands only.

7.9 SS metallic hoses/bellows Boa Ag / Ratty / Powerflex / Witzenmann / Ham-Let.

7.10 Refrigerated circulator Julabo / Huber

7.11 Temperature controllers Eurotherm / Yokogawa / Siemens / Honey well / Athena

7.12 PLC Siemens / Allen Bradley / Ge Fanuc / Omron

7.13 Paperless recorder ( Data Acquisition System)

Eurotherm / Brainchild/ Yokogawa / Honey well / Siemens

7.14 D-sub connector ITT Cannon / Positronic / Souriau / C&K

Note: Vendor shall provide the preferred brands as mentioned above. Vendor shall also provide

detailed justification based on heritage and technological merit etc. where ever equivalent

brands are proposed. However, URSC/ISRO reserves the right to accept or reject the equivalent

brands proposed.

25

8. CRITERIA FOR SYSTEM ACCEPTANCE

The following shall be the criteria for System Acceptance after complete assembly and trial checks.

8.1 Vacuum chamber with VCM test setup (at ambient temperature) shall be evacuated from Atmosphere to less than or equal to 1 x 10-2 mbar in less than or equal to 20 minutes using Roots pumping station.

8.2 Vacuum chamber with VCM test setup (at ambient temperature) shall be evacuated from Atmosphere to less than or equal to 5 x 10-5 mbar in less than or equal to 30 minutes using Cryo pump (excluding cryo pump cool down time).

8.3 Hot bars shall be heated from ambient to + 125°C within 20 minutes.

8.4 The temperature uniformity of Hot bar shall be within ± 0.8°C.

8.5 Cold bars shall be cooled and maintained at + 25°C when Hot bar is at + 125°C.

8.6 The temperature uniformity of Cold bar shall be within ± 0.8 deg C.

8.7 Maintaining the above temperatures for 50 hrs in 10-6 mbar range.

8.8 Demonstrate heating of individual hot bars up to +150°C.

8.9 De-contaminating of hot bar at + 150°C for 5 hrs. with chamber pressure of 10-6 mbar range.

8.10 Ultimate chamber vacuum of ≤ 2 x 10-6 mbar.

8.11 Demonstrate chamber vent control.

8.12 Demonstrate functionality of illumination lamp.

8.13 Functionality of Vacuum and Temperature safety interlocks.

8.14 The cool down time of Second stage in Cryo pump shall be less than or equal to 110 min.

8.15 Demonstrate regeneration of cryo pump.

9. SUPPLY OF SPARES

MANDATORY SPARES TO BE SUPPLIED BY VENDOR

The vendor shall supply the following mandatory spares as part of the contract so as to

ensure that the system will serve reliably after commissioning. The list of spares and

quantity is as below:

Sl. No

Item description Quantity

9.1 VCM Test setup (4.1 to 4.6) 01 set

9.2 Heaters for 08 No. of Hot bars 01 set.

9.3 PT-100 Sensors, Class A, 3 wire type 10 Nos.

9.4 Viton “O “ ring for Chamber. 01 No.

Note: The above mentioned Spares shall be separately packed with BoM and delivered along with the supply of main system.

26

10. TRAINING

After successful installation and commissioning at URSC/ISRO, the vendor shall impart training to URSC/ISRO personnel for system operation, maintenance and setting parameter/editing in PID controllers / PLC / DAQ as applicable.

11. WARRANTY

Warranty period of complete VCM Test System including all parts, components, Instruments, equipment, etc. from the date of acceptance at URSC is 12 months.

12. DELIVERY SCHEDULE

12.1 The time period for delivery including Installation, Commissioning and functional Demonstration at URSC from the date of release of Purchase Order is 10 months.

12.2 Tentative schedule is as given below:

Sl. No. Time Description 12.2.1 TO Release of Purchase Order 12.2.2

TO + 1½ months Submission of Detailed Design Report by the vendor.

12.2.3 TO+ 2 months Detail Design Review at URSC. Clearance for fabrication. 12.2.4 TO+ 8 months Performance evaluation of the complete system at vendor premises

and shifting to URSC after clearing. 12.2.5 TO+ 10 months Completion of installation, Commissioning and performance

validation at URSC.

13. LIST OF DELIVERABLES The list of deliverables and execution of action at respective stages of Project is classified as follows:

13.1 During Detailed Design Review at URSC. Vendor shall present detail design review document after release of Purchase Order as per section 12.0. The detailed design review document shall consist of the following:

13.1.1 Final configuration and design of vacuum chamber, design calculation, mechanical drawing of chamber, support structure, VCM Test setup, etc.

13.1.2 Vacuum system design & calculation such as Roots Pumping Station, Cryo pump with all plumb lines & valves.

13.1.3 Design of heating and cooling system.

13.1.4 Vendor shall attach 3D drawing of entire vacuum chamber, opening & closing arrangements, Ports, pumps, circulator, support structure, complete VCM test setup comprising of Heating bars, Cooling bars, plumb lines, detachable connections etc.,

13.1.5 Detailed test, evaluation and quality assurance plan.

27

13.3 Deliverables after complete Installation at URSC.

13.3.1 The complete VCM test system shall be installed along with all sub systems such as Vacuum system, Thermal system, VCM test setup & Instrumentation and Control.

13.3.2 Conduct Acceptance test as per section 8.0 after installation at URSC / ISRO. 13.3.3 Following are the deliverables after complete installation and commissioning of the

system:

13.3.3.1 Performance test report.

13.3.3.2 Technical data sheet, catalog of all instruments / equipment.

13.3.3.3 Test / Calibration certificates.

13.3.3.4 Operation manual of all equipment / instruments in English.

13.3.3.5 Complete description of the system with operation and maintenance

manual.

13.3.3.6 Electrical system wiring diagram and mechanical part drawing of all the

system elements.

13.3.3.7 All fabrication drawings, control logic details, detailed circuit diagram,

troubleshooting details etc., shall be provided in both hard and soft

form.

13.3.3.8 Mandatory spares as per sec. 9.0.

13.3.3.9 Completion of Training to URSC/ ISRO Staff.

13.3.3.10 Warranty Certificate.

13.2 Deliverables during pre-dispatch clearance: After complete assembly of VCM test system at vendor premises, functional test as per section 8.0 shall be carried out in presence of URSC representative. Following are the deliverables at the time of pre – dispatch clearance:

13.2.1 QA / QC documents for acceptance of all the equipment which are the part of VCM test system.

13.2.2 Test certificate of material conformance, Radiography test, Report of welding.

13.2.3 Details of leak tests conducted with results.

28

14. LEGEND

DDR Detailed Design Review

VCM Volatile Condensable Materials

TML Total Mass Loss

CVCM Collected Volatile Condensable Materials

RGA Residual Gas Analyser

RTD Resistance Temperature Devices

PRT Platinum Resistance Thermometer

RVP Rotary Vane Pump

TIG Tungsten Inert Gas

ASTM American Standard for Testing Materials

DAS Data Acquisition System

SS Stainless Steel

MS Mild Steel

FOS Factor Of Safety

GN2 Gaseous Nitrogen

u/s Under section

BoM Bill of Materials

Std. Standard

CMH Cubic Meter per Hour

m3/hr Cubic Meter per Hour

MSLD Mass Spectrometer Leak Detector

BoM Bill of Materials

URSC U.R. Rao Satellite Centre (formerly ISRO Satellite Centre)

29

Fig. 1

30

Fig. 2

31

Fig. 3

32

Fig. 4

33

Fig. 5

34

Fig. 6

35

Fig. 7

36

Fig. 8

37

Fig. 9

38

Fig. 10

39

Fig.11

40

Fig. 12

41

Fig. 13

42

Fig. 14

43

CONFIGURATION OF VCM TEST SETUP

Fig. 15

HOT BAR

3.8± 0.05mm

44

Annexure- I Compliance Statement of VCM Test System

(Vendor shall completely fill the compliance statement and submit along with quote.) REF. No. Description Technical

Specification Vendor’s Response Vendor’s

Ref. Page No.

1.0 Scope of Contract As described

1.1 Heritage As described

1.2 Introduction As described

1.2.1 Vacuum Chamber As described

1.2.2 Vacuum pumping system As described

1.2.3 VCM Test setup As described

1.2.4 Thermal System As described

1.2.5 Instrumentation & Control As described

1.3.1 to 1.3.16

General Requirements, As described

1.4.1 to 1.4.3

Scope of Supplies from URSC / ISRO.

As described

2.1.1 Base adapter dimensions

a. Inner diameter: 650 mm

b. Height: ( clear inner height )

180 mm

2.1.2 Top Chamber

a. Inner Diameter: 650 mm

b. Height 450 mm

2.2.1 to 2.2.3

Configuration of chamber As described

2.3 Hoist As described

2.4 Guide Rod As described

2.5.1 to 2.5.2

Material of Construction As described

2.6.1 to 2.6.5

Design guide lines As described

2.7.1 to 2.7.9

Instruction for fabrication of chamber

As described

2.8.1 to 2.8.4

Inspection & Quality control Requirements

As described

2.8.5 Chamber Ports details ( Tentative) Total: 17 ports

As described

2.9 View Port, 01 No. As described

3.1.1 to 3.1.7

Technical specification of Roots pump, 01 No.

As described

3.1.8 to 3.1.18

Technical specification of Rotary Vane Pump, 01 No.

As described

3.2 Cryo Pump - 01 No. As described

3.2.1 to 3.2.9

Technical specification of Cryo pump

As described

3.3 Vacuum Valves As described

3.3.1.1 to 3.3.1.13

Technical specification of high vacuum gate valve

As described

45

REF. No. Description Technical Specification

Vendor’s Response Vendor’s Ref.

Page No.

3.3.2.1 DN 63 ISO Electro -pneumatically operated valve,

On Base adapter for Chamber roughing, 01 No.

As described in 3.3.3.1 to

3.3.3.5

3.3.2.2 DN 40 KF Electro pneumatically operated valve, in fore line of Cryo pump, 01 No.

3.3.2.3 DN 10 / 16 KF Electrically operated valve for Chamber vent, 01 No.

3.3.2.4 DN25/40 KF Manually operated valve for Piezo gauge , 01 No.

3.4.1

Operational Vacuum: Atmosphere to 1 x 10-2 mbar

in less than or equal to 20 minutes using Roots station.

3.4.2 Operational Vacuum: Atmosphere to ≤ 5 x 10-5 mbar

in less than or equal to 30 minutes using Cryo pump (excluding cryo pump cool down time).

3.5 Gas loads for vacuum system sizing

As described

3.6.1 to 3.6.2

Vacuum system requirement As described

3.7 Leak Tightness less than 1 x10-8 mbar-l/s (He).

3.8.1 to 3.8.5

Venting and Purging system As described

4.1 VCM Test setup Hot Bar, 04 No.

As described

4.2 Cold Bar, 02 No. As described

4.3 Separator plate, 04 No. As described

4.4 Collector plate, 32 No. As described

4.5 Cover plate, 32No. As described

4.6 Base plate with legs, 01 No. As described

4.7 Alignment of VCM Test setup As described

5.1 Heating system As described

5.2 Cooling system As described

5.3.1 to 5.3.11

Technical specification of Refrigerated circulator, 01 No.

As described

46

REF. No. Description Technical Specification

Vendor’s Response Vendor’s Ref.

Page No.

6.1.1 To 6.1.11

Instrumentation & Control system

As described

6.2.1 to 6.2.9

Instrumentation & Control system - Hardware

As described

6.3.1.1 to 6.3.1.4

Programmable Logic Controller, 01 No.

As described

6.4.1 to 6.4.10

Electrical switch gear / power panels

As described

6.5.1.1 to 6.5.1.15

Technical specification of Pirani gauge head, 02 No. Display & Control Unit, 01 No.

As described

6.5.2.1 to 6.5.2.24

Technical specification of Compact Full Range gauge head, 01 No. Display & Control Unit,01 No.

As described

6.5.3.1 to 6.5.3.12

Technical specification of Digital Absolute Pressure gauge, 01 No. Display Unit, 01 No.

As described

6.6 Data logging, As described

6.6.1.1 to 6.6.1.20

Technical specification of Data logger / Paperless Recorder, 01 No.

As described

6.6.2 Alarm / Hooter / Tower light As described

6.6.3 Temperature sensor, 16 No. As described

6.7.1 to 6.7.15

Technical specification of PID based Temperature controller, 04 No.

As described

6.8.1 to

6.8.3

Electrical heaters for 4 No. of Hot Bars ( excluding spares)

As described

6.9.1.1 to 6.9.1.18

Technical specification of Electrical / Signal feedthrough, 01 No.

As described

6.9.2.1 to 6.9.2.4

Technical specification of Power feedthrough

As described

6.10.1 to 6.10.2

Illumination lamp inside Vacuum chamber, 01 set.

As described

6.11.1 to 6.11.10

General Requirements of Instrumentation & Control System

As described

7.1 to

7.14

Source of supplies for Critical Items

As described

8.1 to

8.15

Criteria for System Acceptance As described

47

REF. No. Description Technical Specification

Vendor’s Response Vendor’s Ref.

Page No.

9.1

Supply of Spares: VCM Test setup (4.1 to 4.6)

01 set

9.2 Heaters for 08 No. of Hot bars 01 set

9.3 Pt – 100 Sensor, Class A, 2 wire type

10 No.

9.4 Viton “O “ ring for chamber. 01 No.

10.0 Training As described

11.0 Warranty 12 months

12.1 Delivery schedule As described

12.2.1 To

12.2.5

Tentative Schedule As described

13.1 .1 to 13.1.5

List of Deliverables During Design Review at URSC

As described

13.2 .1 to

13.2.3

Deliverables during pre-dispatch clearance.

As described

13.3.1 to

13.3.3

Deliverables after complete installation at URSC

As described

13.3.3.1 Performance test report as per section 8.0 after installation at site.

Shall be Provided

13.3.3.2 Technical data sheet, catalogue of all instruments / equipment.

Shall be Provided

13.3.3.3 Test / Calibration certificates. Shall be Provided

13.3.3.4 Operation manual of all equipment / instruments in English.

Shall be Provided

13.3.3.5 Complete description of the system with operation and maintenance manual.

Shall be Provided

13.3.3.6 Electrical system wiring diagram and mechanical part drawing of all the system elements.

Shall be Provided

13.3.3.7 All fabrication drawings, control logic details, detailed circuit diagram, troubleshooting details etc., shall be provided in both hard and soft form.

Shall be Provided

13.3.3.8 Mandatory spares as per sec. 9.0.

Shall be Provided

13.3.3.9 Completion of Training to URSC/ ISRO Staff.

Shall be Provided

13.3.3.10 Warranty Certificate Shall be Provided