Request for Proposal on automation of leak check operations … · 2018. 2. 12. · Make : Pfeiffer Vacuum MODEL NO: HLT 260: HLT 560: ASM310. Request for Proposal on automation of

Request for Proposal on automation of leak check operationsScope of work and services

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Request for Proposal for Supply, Installation andCommissioning of Automation system for Leak Check

Operations.


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Table of content

SL NO. CHAPTER PAGE NO.

1 INTRODUCTION 3

2. BRIEF DESCRIPTION OF LEAK CHECK OPERATIONS 3-4

3. DESCRPTION OF EXISTING FACILITY ANDSPECIFICATION OF THE EXISTING ITEMS.

4-7

4. ELECTRICAL SINGAL LINE DIAGRAM FOR EXISTINGFACILITY

7

5. OBJECTIVE 8-9

6. CONTROL SYSTEM REQUIREMENT 9-10

7. SCOPE OF SERVICES FROM DEPARTMENT 10-11

8. SCOPE OF WORK BY VENDOR 12-46

9. RECOMMENDED SUPPLIER/MAKE(ANNEXURE I)

47-48

10. DATABASE STRUCTURE FOR CRYO LEAKAUTOMATION

49-53


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1. INTRODUCTION

ISRO Propulsion Complex (IPRC) of Indian Space Research Organisation(herein after referred to as the “Department”) intends to automate itsexisting system for leak check operations for propulsion systems. Thedepartment invites bids from potential vendors for realising a PLC basedcontrol system to control, monitor, acquire and store the data.

The scope of work under this RFP by the vendor is to establish completeautomation system through design, procurement, development, installation& commissioning according to department finalized specifications given inthis RFP.

2. BRIEF DESCRIPTION OF THE LEAK CHECK OPERATIONS

Leak check is one of the most critical activities of propulsion systemintegration. After integration, systems are leak tested to prove theirintegrity. The possibility of leakage in systems or products which contain gas,vacuum or liquids is of concern. Prevention of material loss from a system orproduct, the maintenance of the vacuum integrity of a system or productsand the reliability of a system or product can all depend on efficientdetection and measurement of leakage .The propulsion systems are leaktested by various methods. In case of propulsion system the leak testingoperation is very crucial and the checks are done by following methods:-

1. Pressure drop method

2. MSLD detector probe method

3. Global vacuum leakage check method

These leak check operations involves various activities as described below


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LEAK CHECK BY PRESSURE DROP METHOD

Leak check by pressure drop method is used to find the leak in the system bypressurising it for a fixed duration of time and noting the drop in pressure inholding condition. The activities include pressurization of the hardware andlogging of the pressure data.

LEAK CHECK BY MSLD DETECTOR PROBE METHOD

Leak check by MSLD detector probe method is used for finding the leakcheck of individual joints of systems, eg: Flange joints, threaded joints andweld joints. Helium is used as the tracer gas for this method of leak check.There are many joints in individual system and each joint leakage rate has tobe logged individually.

LEAK CHECK BY GLOBAL VACUUM METHOD

Vacuum leak test is done to measure the total leak rate of the assembledhardware before delivering the hardware for further operations.

The vacuum leak test facility consists of the following major systems

Vacuum chamber I Vacuum chamber II Vacuum chamber III Vacuum pumping systems for the above chambers Helium mass spectrometer leak detector (MSLD) Chiller unit (For cold water supply to diffusion pump & rotary pump) Compressor unit (For Command gas pressure) Pressurization test rig

The operation involves operation of vacuum pumps, chiller unit, compressorand electro-pneumatic valves. All the operations are at present done manuallywhich is highly operator dependent.

3. DESCRPTION OF EXISTING FACILITY AND SPECIFICATION OF THE EXISTINGITEMS.

BRIEF DESCRIPTION OF EXISTING FACILITY


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1. Pressurization test rig - 2 nos.2. Vacuum chamber - 3 nos.3. Vacuum pump - 9 nos.4. Helium leak detector - 3 nos.5. Air compressor - 2 nos.6. Water pump - 2 nos.7. Chiller plant - 2 nos.

3.1 SPECIFICATIONS FOR EXISTING VACUUM PUMPS, AIR COMPRESSORAND WATER PUMP

1. ROTARY VACUUM PUMP- 1 and 2

PARAMETER RVP-1 RVP-2POWER, kW 5.5 5.5CURRENT, A 10.7 10.7VOLTAGE ,V 415 415Speed, rpm 1440 1440FREQUENCY, Hz 50 50

2. ROTARY VACUUM PUMP- 3

PARAMETER RVP -3POWER, kW 7.5CURRENT, A 11VOLTAGE ,V 210-230Speed, rpm 970FREQUENCY, Hz 50

3. ROOT PUMP -1

PARAMETER ROOT-1POWER, kW 5.5CURRENT, A 10.5VOLTAGE ,V 415Speed, rpm 2870FREQUENCY, Hz 50


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4. ROOT PUMP-2

PARAMETER ROOT-2POWER,kW 5.5VOLTAGE ,V 230FREQUENCY, Hz 50Speed, rpm 2870CURRENT, A 10.5

5. DIFUSSION PUMP

PARAMETER PUMP-1 PUMP-2 PUMP-3 &4

VOLTAGE , V 230 230 230

POWER, W 2200 3750 7500

6. COMPRESSOR

PARAMETER COMPRESSOR-1 COMPRESSOR-2

Power, kW 5.5 2.2

Frequency, Hz 50 50

VOLTAGE , V 415 415

CURRENT, A 11.5 6.2

Speed, rpm 420 140

7. WATER PUMP

PARAMETER PUMP-1 PUMP-2

Power, kW 2.2 2


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8. MSLD

4. ELECTRICAL SINGLE LINE DIAGRAM FOR THE EXISTING FACILITY IS ASFOLLOWS:

Presently all these equipments are operational. All the above mentionedequipments are now operated manually through electrical switches and loggingof the leak check data is being done manually.

CURRENT, A 5 4.7

VOLTAGE , V 415 415

FREQUENCY, Hz 50 50

Make : Pfeiffer Vacuum

MODEL NO: HLT 260: HLT 560: ASM310


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5. OBJECTIVE

The primary objectives of the automation of leak check operations are asfollows:

Introduction of PLC based control system with operator console for dataacquisition & control is to reduce manual intervention, logging of data andperforming closed loop operations of vacuum leak test facility to facilitate timebound, error free & efficient operation. The proposed system is to be built withPLC based controller with I/Os located in the same location. The system should befail-safe & robust. The PLC, data server and three operator station nodes are to bepositioned at a safe distance from the existing facility, preferably 8 metres. Thebasic architecture that needs to be incorporated is shown below:

PLC

MAIN DATASERVER

SCADALOADING

CLIENT 1

CLIENT 3

CLIENT 2

Leak check bypressure drop

method

Leak check byMSLD Sniffing

Vacuum Leakcheck

1.All the client can do only one operation at a time out of the three operations.2. All the clients need to be capable of performing any of the three leak check operations

simultaneously.

The architecture of the total system shall be such that any of the client node(operator station) should be able to perform any of the 3-leak check operations(Leak check by pressure drop or by MSLD detector probe or by global vacuum leakcheck) simultaneously, except those for which the relevant channels are accessedby the other client nodes.Some example combinations are given below


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SL NO Client 1 Client 2 Client 31 Pressure drop

methodMSLD TracerProbe method

Vacuum Leakcheck method

2 Pressure dropmethod

Pressure dropmethod

Pressure dropmethod

3 MSLD TracerProbe method

MSLD TracerProbe method


4 Pressure dropmethod



5 Vacuum Leakcheck method

Pressure dropmethod


6 MSLD TracerProbe method

Vacuum Leakcheck method

Pressure dropmethod

And so on for all 9 combinations of leak checks

6. CONTROL SYSTEM REQUIREMENT

a. CONCEPT OF CONTROL SYSTEM

a) PLC based control system, Client-Server configuration with SCADA/HMIfor automation of leak check operations. All process parameterscommunicate with control system through I/O modules.

b) The control system is to control, monitor, acquire and store the status offield elements.

c) The Instrumentation concept shall be such that the process can becontrolled through SCADA/HMI.

d) Process parameters which are to be measured are in the form of voltageor current in the range of 0-10 Volt, 0-100 mV & 4-20 mA as analoginputs.

e) Digital input/output should be in the range of 0-24 V DC.f) Programming, Graphics development and database creation should be as

per control philosophy of the facility.g) Interlock, logic, Process variable measurement etc. shall be considered in

the concept of control system.b. CONTROL SYSTEM REQUIREMENT DETAILS


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SLNO ITEMS QTY TECHNICAL SPECIFICATION

1 PLC Analog inputchannel

Digital Input Digital Output

Type ofinputchannel

Channelcount

Type ofinputchannel

Channelcount

Type ofinputchannel

Channelcount

Ampereinput

30 NOS. Voltlevel

40 NOS. 3Ø-relaycontrol

25 NOS.

millivoltinput

20 NOS. RS232 1 no. Voltlevel

25 NOS.

Voltinput

15 no. RS485 1 no.

2. Dataacquisition

Should be done by thecontrol PLC Itself and dumpedto a data server.

3. Pressuretransmitter

8 NOS.8 NOS.2 NOS.

Range 0-10 bar absoluteRange 0-30 bar absoluteRange 0-500 mbar differential

4. Temperaturetransmitter

5 nos. 5 NOS. 0 to 60 degree Celsius

5. EP valves 5 types ½ inch-2nos1 ½ inch-3nos4 inch 3nos6 inch- 1nosKF 25 – 3 nos

6. Operatorstation withprinter

3 nos Specification sheet attachedas annexure

7. Main dataserver

1no Specification sheet attachedas annexure

7. SCOPE OF SERVICES FROM DEPARTMENT

a) The command tubing for all above mentioned EP valves connected to thesystem by the vendor will be carried out by department.

b) Thermocouple connected on to the diffusion pump body will be departmentscope and free-end will be provided for interfacing with the PLC.

c) All vacuum pumps, compressors, chiller unit, water pump, water tank and EPvalves as shown in figure 1 are already installed at department premises


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except the items marked in red colour. These red colour items to beprocured as per the list of items and to be installed by the vendor in theexisting system, apart from PLC based control system that is to becompletely designed developed and installed by the vendor. All Piranigauges, cold-cathode gauges, valve positioner, controller for gauges arealready installed in the system.


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8. SCOPE OF WORK BY VENDOR

8.1 Design

The vendor shall carryout the necessary design to realise the automationsystem as per this RFP , basic configuration is shown below.

8.2 Procurement

The vendor shall procure all necessary hardware and develop thenecessary software to realise the automation system in its presentconfiguration and provide integrated development environment for thefuture customisation of the SCADA/HMI by the department. List of itemsto be procured and their specification is mentioned below:

8.2.1 LIST OF ITEMS


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Sl.No Item Qty

1. PLC based control system 1 no

2. Data server 1 no

3. Operator station 3 nos.

4. Electro pneumatic valves 1. ½ inch-2nos2. 1 ½ inch-3nos3. 4 inch 3nos4. 6 inch- 1nos5. KF 25 – 3 nos

5. Pressure transmitter

(Local display is not neededfor 5 nos. being mounted inpressure drop methodmanifold for 10 bar & 30 barrange each.)

Range

1. 0-10 bar absolute 8 nos.2. 0-30 bar absolute 8 nos.3. 0-500 mbar differential

2 nos.

6. Temperature transmitter Range0- 60 degree Celsius - 5 nos.

7. Relays 3Ø - 20 nos (conventionalelectromechanical type)

1Ø – 25 nos. (Solid staterelays)

8. Cables

(Power cabling for theequipments already installedby the department shall beretained. Vendor scope is tocarry out control caballingupto the control elements ofthe respective equipments)

Length to be determined bythe vendor. Existing systemlayout and proposed PLCrack, data-server andoperator station location isshown in below mentionedfigure2.


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9. Printer (A4) 1 no

10. Leak check manifold 5 nos as shown in figure3 inchapter no 5.3.1

Note: pressure transmitteras shown in the figure needto be used from item no 5 inthe list as per the requiredrange.


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8.2.2 Specification of items

1) Specification of control system

Sl.No Specification Required As perquote

1 General1.1 Control System Stand alone PLC

FIGURE 2


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1.2 Cycle time (Scan time)including I/O and 128Kapplication program

50 msec

1.3 Event Data Acquisition 50 msec1.4 Analog Data Acquisition 200msec1.5 Data updation in SCADA 1 sec1.6 Auto sequence command

generation100msec

1.7 Data of analog and digital I/Oat PLC level

50 msec

1.8 Operating Temperature 0-50 Deg.C1.9 Humidity 0-95 %, non

condensing1.10 PLC programming languages As per IEC 61131-31.11 SCADA 300 Tags1.12 Diagnostic feature Required1.13 Data Logging Required1.14 Offline data processing SCADA node1.15 Ethernet 100/1000 Mbps1.16 Data base for analog and

digital dataRequired

1.17 Data mix up in SCADA Required1.18 Provision to display the

parameters in mimicacquired using another dataacquisition

Required

1.19 Provision to start /stop theacquisition without affectingthe functioning of the controlsystem

Required


2 ANALOG INPUT MODULE2.1 No. of channels 82.2 Resolution ≥ 14 bit2.3 Filter response time for 63%

of F. S8 to 25 msec

2.4 Filter Bandwidth 6 to 20 Hz2.5 Voltage input Impedance > 1 M ohms2.6 Current input Impedance < 250 ohms2.7 Accuracy ± 0.2 %2.8 Conversion time < 20 msec2.9 Electrical Isolation > 250 V rms


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2.10 Common mode noise rejection > 80 db


3 DIGITAL INPUT MODULE3.1 No. of inputs 16/323.2 Input voltage(Nominal) 24 V DC3.3 Input voltage(Maximum) 30 V DC3.4 Switching Threshold Low < 5V3.5 Switching Threshold High > 10V3.6 Input Resistance > 2KΩ3.7 Switching Delay < 2msec3.8 Input Current < 10 mA3.9 Electrical Isolation > 250 V rms


4 DIGITAL OUTPUT MODULE4.1 No. of Outputs 16/32

4.2 Type Transistor4.3 Output Voltage 24 V DC4.4 ON/OFF Switching Delay < 1 mSec4.5 Current Per Output > 0.2 A4.6 Electrical Isolation > 250 V rms


5 Software5.1 Run time Required5.2 Development Required5.3 Real time Required5.4 Data Acquisition Required5.5 Data retrieval & offline

processingRequired

5.6 Application software Required

Sl.No Specification Required As per quote

6Single phase Relays (Solidstate)

6.1 Control voltage 10 – 24 V DC


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6.2 Controlled voltage 230 V ac 50 Hz

6.3 Current being controlled 200 mA minimum

7Three phase Relays (Electromechanical relays)

7.1 Control voltage 10 – 24 V DC

7.2 Controlled voltage 415 V ac, 50 Hz, 3Ø

7.3Current being controlled ineach phase

12A nominal, withsurge ratings upto50A

2Specification of data server

Supply & Installation of Server with 2 X Intel 8 core or more Xeon processorE5-2690v2 series @ 3.0 GHz or more with 25 MB cache.

Processor 2 x Intel 8 core or more Xeon processor E5-2690v2 series

@ 3.0 GHz or more with 25 MB cache.

Memory 32 GB (2x16 GB or better) ECC DDR3 memory @ 1600

MHz

Drive Bays 8 or more x 2.5” / 3.5” for SAS hot plug drives.

Drive Controller Integrated or add-on SAS controller.

Hard Disk drives 6 x 600 GB SAS HDD 6G (10 K RPM)

RAID Controller Onboard or add-on RAID controller to configure RAID 6

with 512 MB Cache.

Removable media DVD-RW supermulti, slim line SATA.

Expansion slots 4 slots or more after configuring the requirements.


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Bus slots Four PCI-Express slots or more.

Graphics Integrated Graphics controller.

Network on board - 2 x 1G Ethernet ports and additional 2x 1G

Ethernet port (External).

I/O ports & Connectors 4 USB.

Power supply 2x hot plug power supply (230V @ 50 Hz) Unit.

Power 230V @ 50 Hz, Indian power cords to be supplied.

Form factor Rack – Server depth should not exceed 780 mm.

Fan Five or more hot-plug fans.

Software System management software

Rack Mountable 2U size

Warranty 3 Years

Note: 19” Rack Mountable Kit should be supplied along with servers.

1. 1U Size 19” Rack Mountable Foldable LCD Monitor

Computer Connections 1

Console Selection Hotkey

Connectors External Console Ports: Keyboard (1 x 6 –pin Mini-Din

Female, 1

x USB Type A Female), Video (1 x HDB-15 Female), Mouse

(1 x 6 –pin Mini-Din Female, 1 x USB Type A Female)

KVM Ports: 1 x SPHD-15 Female

Power: 1 x 3-prong AC Socket

F/W Upgrade: 1 x RJ-11

External Mouse: 1 x USB Type A Female

Switches Reset: 1 x semi-recessed Pushbutton

Power: 1 x Rocker

F/W Upgrade: 1 x slide


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LCD power: 1 x Pushbutton

LCD Adjustment: 4 x Pushbutton

LEDs Power: 1

Lock: 1 x Num Lock, 1 x Caps Lock, 1 x Scroll Lock

Emulation Keyboard/Mouse: PS/2, USB

Video 19” LCD: 1280 x 1024, DDC2B

Power Rating 100-240AC, 50-60 Hz, 1A

Environment Operating Temperature: 0-40oC

Storage Temperature: -20-60oC

Humidity: 0-80% RH, Non-condensing

Physical Housing: Metal

Note: 19” Rack Mountable Kit should be supplied along with Monitors.

Note: The quotations should be accompanied with detailed product

Specifications and compliance statement. The quotations without Brand name,Model No. will not be considered.

2. SPECIFICATION OF OPERATOR STATION


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3.4.Specification of EP valves

4.1 6 inch&4 inch vacuum gate valve specification

Parameter Specification

Leak rate : valvebody, valve seat

<1x10-9 mbarl/s

Pressure range 1x10-7 mbar to 1.2 bar

1. PROCESSOR- Intel core i5-6600 processor(4 cores/ 4threads,3.30 GHz or higher,6 MB, Intel HD graphics 530)

2. MEMORY- 4 GB DDR3 or latest with 16 GB Expandability3. HARD DISK- 1000GB 7200 rpm SATA III hard drive with

minimum four partitions4. NETWORK- 100/1000 on board integrated network port5. PORTS- USB 6NOS. 2x USB 3.0 minimum , 1x microphone, 1x

headphone, VGA, DVI, 1X AUDIO LINE IN, 1 XAUDIO LINEOUT

6. EXPANSION- 1X PCIEX16(MINIMUM), 1X PCI LEGACY(MINIMUM)

7. AUDIO-INTEGRATED HD AUDIO8. KEYBOARD- USB2.0 multimedia keyboard9. Mouse- USB optical scroll mouse10. DVD drive – 16 XDVD+/- RW DUAL LAYER R/W11. Cabinet – mini tower/ tower12. Monitor -47 cm or larger TFT/ LED digital colour monitor –

TCO-05 certified13. Software- windows 8.1 or higher preloaded with media and

authenticity of certification14. Power supply -50 HZ, 230v ac with Indian standard. Plug

tops. Power supply SMPS surge protected.15. Certifications –regulatory certifications ecology, energy ,

ergonomics, emissions


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Cycle until firstservice

100000

Temperature range 5- 80 degree Celsius

Material : valvebody

SS304L

Material : seal VITON

Mountingorientation

Any

Solenoid valve 220 v

Position indicator :

Voltage:

Current:

<250v

<2A

Valve positionindication

Apart from remoteposition there shall be alocal visual indication.

Valve mountingflange dimensionexisting in thesystem.

(valve end flangesshould match thesedimensions)

6inch- ODØ254,PCD 230 ,Ø11X4 HOLLES

4inch- ODØ178,PCD 159.5 ,Ø9X4 HOLLES

Valve operation By pneumaticactuator withcommand gas at6to 8 bar(g)pressure.

4.2 ISO DN KF 25 ELECTRO PNEUMATIC VALVE.


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Parameter Specification

Leak rate : valvebody, valve seat

<1x10-9 mbarl/s

Pressure range 1x10-7 mbar to 5 bar

Cycle until firstservice

100000

Temperature range 5- 80 degree Celsius

Material : valvebody

ALUMINIUM

Material : seal VITON

Mountingorientation

Any

Solenoid valve 220 v

Position indicator :

Voltage:

Current:

<250v

<2A

Valve positionindication

Apart from remoteposition there shall be alocal visual indication.

Valve mountingflange dimension

KF 25

Valve operation By pneumatic actuatorwith command gas at6to 8 bar(g) pressure.

4.3 ½ inch and 1 ½ inch EP VALVE


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PATTERN BALL

APPLICATION SHUT OFF/ISOLATION/ON-OFF

ACTUATION ELECTRO PNEUMATIC

FLUID MEDIUM WATER, GN2, GHe &AIR

PRESSURE 20 BAR(max)

BODY MATERIAL SS 304L/SS 316L

PERMISSIBLE LEAKAGERATE

BUBBLE TIGHT

GUARANTEED CYCLESOF OPERATION

10,000

END CONNECTION TO BE DECIDED BY THE VENDOR AS THECOUNTER PART IN THE PIPE ASSEMBLYHAS TO BE INSTALLED BY THE VENDOR.

Valve operation By pneumatic actuator with command gasat 6to 8 bar(g) pressure.

5. SPECIFICATION OF PRESSURE TRANSMITTER

Accuracy <±0.5% BFSL

Over pressure range 2x rated pressure, minimum

Burst pressure 5x or 20,000 PSI(whichever is less)

Pressure cycle >100 million

Operating temperature 5- 80 degree Celsius

EMI/RFI protection yes

Electrical data Output 4-20 mA


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Excitation 10- 28 VDC

Current consumption 20 mA, typical

6. SPECIFICATION OF TEMPERATURE TRANSMITTER.

Temperature range 1. 10 -400 degree Celsius2. 8- 60 degree Celsius

Permissible basic error limit ±2 degree Celsius

Material of the assembly part ofprotective armoure

SS

Recommended supplier/ make for the above mentioned items are mentioned inANNEXURE I .No other suppliers/make items will be considered.

8.3 INSTALLATION AND COMMISSIONING OF THE SYSTEM

Installation includes cable laying for the entire system, mounting ofmeasurement sensor, giving proper electrical connection to the control system,PLC program development, HMI/SCADA interface development for controllingthe system. Commissioning of the system comprises of PLC programming forclosed loop operations, data acquisition from various sources & storing in dataserver, data display and trial runs for the various scenarios of the entire system.

8.3.1 WORK TO BE CARRIED OUT FOR LEAK CHECK BY PRESSURE DROP METHOD

For conducting leak check by pressure drop method, work to be executed isdivided into two categories i.e. mechanical and software category.

SCOPE OF WORK FOR MECHANICAL PART

Five separate leak check manifolds are to be made as per the drawing shownbelow. The material of construction of parts shall be austenitic stainlesssteel of 304L / 316L grade.


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SCOPE OF WORK FOR SOFTWARE PART

Software part basically includes creating database structure (refer AnnexureII) and entering relevant data which will be provided after award of contract(~50 nos. of entries) for various hardware, creating mimic diagrams anddisplay pages a shown below as front end for data entry, data acquisition,displaying results and data logging.

SL NO ITEMS SPECIFICATION1 TUBE TUBE OD : 10 mm

TUBE THICKNESS : 2mm

2 ISOLATION PNEUMATICVALVE(SWAGELOK MAKE orparker)

UPSTREAM PRESSURE:250 bar(max)DOWNSTREAMPRESSURE: 100 bar(max)

3 PRESSURE TRANSMITTER 3a - RANGE : 0-30 bar(a)3b- RANGE: 0-10 bar(a)

4 FILTER( SWAGELOK MAKEor parker)

2 MICRON

5 INLET JOINT M14X 1.5 , MALEADAPTOR

6 OUTLET JOINT M14X 1.5 NIPPLE & NUT

Gas inlet Gas outlet

1 2

3a

46

5

3b

FIGURE 3


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Leak check by pressure drop methodHARDWARE NAME:

HARDWARE ID NO:

PRESSURE TO BE APPLIED:

P :INITIAL

P :FINAL

SAVE

DURATION :

TIMER00:00

T

P1

HARDWARE

PU

Px bar

Pressure drop rate =(P1-P2)/T mbar/sec

Py bar

Leakage rate = (P1-P2)*V/Tmbarl/sec

REMARKS

TEST NO:

MANIFOLD TAG NO:

VOLUME OF TEST ARTICLE:

All the fields should be enabled only on pressing the “START” button and PLCshould start

1. Hardware name :Initially a database structure (with fields for hardware name, hardwarepressure, volume and duration of test) need to be created and entries to bemade for the first time by the vendor at IPRC Site)A drop down menu (populated with already entered hardware names in thedatabase) should be made available for the user to select from. Theselection of hardware name should automatically fill up fields for “pressureto be applied”, “Duration” and “Volume of Test Article”.

2. Hardware id no. to be entered by the operator (Text box).3. Pressure to be applied: Automatically loaded during step1 and also Text box

for entry by the operator is needed, if there is a change in test pressure.4. Test no. (Sequential for a particular Hardware ID no.) is to be auto generated

starting with R0 and if the leak check is repeated for the same hardwarename and id no., the number should sequence through R1, R2 and so on.

5. Manifold number (retrieved from manifold data table) shall be selectablefrom drop down menu.

6. Duration: Automatically loaded in the step 1, also provision to enter datathrough a text box is needed.

START


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7. The volume of the article should be automatically loaded during step 1, alsoprovision to enter data through a text box is needed.

8. P initial: Once the hardware is pressurized to the rated pressure, if thepressure fluctuation is within 1% of nominal pressure to be applied, p-initialhas to be acquired and displayed in the mimic.

9. P final: Once the p-initial has been logged, timer should start and at the endof timer (determined automatically by duration of test) p-final needs to belogged.

10. Leakage rate: to be calculated based on the above formula.11. Pressure drop rate: to be calculated based on the above formula.12. Once the save button is pressed all relevant data should be saved into

database( wherever optional text box for data entry is available ,it shouldtake precedence if it is filled).

13. Data to be retrieved (from the final test no for the particular hardware id)and printed in the following format.

Mimic diagram to the above requirements needs to be displayed. P vs Tgraph need to be displayed during entire operation.(Aesthetic shall bedecided by the vendor)

WORK TO BE CARRIED OUT FOR LEAK CHECK BY MSLD DETECTOR PROBEMETHOD

MSLD detector probe method is used to conduct leak check of individualjoints of propulsion system joints and its sub-assemblies. Entire work isdivided into two categories similar to the pressure drop method.

Mechanical part: same setup will be used as was used for pressure dropmethod.

Hardware nameHardware idPressure appliedDurationInitial pressureFinal pressurePressure drop rate (bar/ minute)


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Software part:

Leak check by MSLD DETECTOR PROBE METHOD

HARDWARE NAME:

HARDWARE ID NO:

MSLD BG :

P :LIVE

SINO

LEGEND TESTNO

LEAKAGERATE(max b/w startand end)

REPEAT PRESSURE

REMARKS

Start End

barHARDWARE

MSLD

SAVE

PxPY barMSLD ID NO :

TT

LEAKAGERATEmbarl/s

Leakage rate field should change colour depending on leakage ratespecification

All the fields should be enabled only on pressing the “START” button and PLCshould start acquisition

1. Hardware name :To be retrieved from the hardware data table.

2. Hardware ID: ID to be entered by operator (Text box).3. MSLD BG: It should be live display which should freeze when the MSLD BG

button is pressed.4. Legend : to be automatically populated from legend data table

corresponding to the particular hardware name.5. Test no. (Sequential for a particular legend is to be auto generated starting

with R0 and if the leak check is repeated for the same legend , the numbershould sequence through R1, R2 and so on.

6. Leakage rate consist of two radio button; once the operator clicks the startbutton MSLD value can be compared against the previous maximum and

START


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comparison ends with the operator pressing the end button, and the fieldshould display maximum value.

7. In the leakage rate column value greater than 5 x 10-7 mbarl/s should beautomatically shown in red color.8. Once the operator clicks the repeat radio button of red color value

automatically one more row will be generated with an auto incrementedtest no. and again the leakage rate value can be captured in leakage ratecolumn for that particular legend.

9. Mimic drawing need to be displayed as shown above.10.Save button be provided.

11.Data to be retrieved (from the final test no for the particular hardware id)and printed in the following format.

Legend Leak rate(mbarl/s)

LEAK CHECK BY VACUUM METHOD

Vacuum leak test is done to measure the total leak rate of the propulsionsystem and its sub systems before delivering for hot test or flight

The vacuum leak test facility consists of the following major systems

Hardware nameHardware idPressure applied


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Vacuum chamber I Vacuum chamber II Vacuum chamber III Vacuum pumping systems for the above chambers Helium leak detector

Automation of operation of vacuum leak check system needs to be done usingPLC based control system ,pressure transmitters, EP valves and temperaturesensors etc (by vendor).

MIMIC DRAWING FOR VACUUM LEAK TEST FACILITY


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Department will free-issue sensor like Pirani gauge, Cold Cathode gauge,thermocouples, mass spectrometer leak detector.

There are three independent vacuum leak check chambers of varying volumes,with the largest being vacuum chamber 1 followed by vacuum chamber 2 &vacuum chamber 3. Each vacuum chamber has independent vacuummeasurement sensors, one Pirani gauge for measurements down to 10-3 mbarand one cold cathode gauge for measurements down to 10-10 mbar. Theevacuation of the vacuum chambers is assisted by 3 pumps working in tandem.The Diffusion pump at the top and backed by the root pump which in-turn isbacked by the Rotary vane pump.

The Root pump along with Rotary vane pump creates rough vacuum for thediffusion pump to take over. Initially the valve connecting the diffusion pump tothe vacuum chamber is closed and that connecting the Root pump / Rotaryvane pump combination to the vacuum chamber is open. Once the roughvacuum is created the roughing valve is closed and the diffusion pump isswitched ON and backed by the Root pump / Rotary vane pump combination.On reaching the working temperature the high vacuum valve is opened and thediffusion pump further reduces the pressure inside the vacuum chamber till theoperational level is attained for the desired application.

All the 3 vacuum chambers operate in a similar fashion but the vacuum creationtime varies due to the varying volumes of the chambers.

The Root pump & the Rotary vane pump are common for all the three vacuumchambers and connected through a common pipe line downstream of thediffusion pumps of the vacuum chambers with one pirani gauge connected formonitoring the evacuation progress. The isolation of the three vacuumchambers is achieved by utilizing valves in high vacuum lines I, roughing line &Diffusion pump line of each chamber. They are all pilot operated solenoidvalves (AC operated).

The major interlock needed is the non-operation of the vacuum chamberswhich are not in operation once the desired vacuum chamber is selected. Allvalves & diffusion pumps of non-operational chambers should be closed & shut-off.


33

Human Interface

The Human interface should be in the form of a MIMIC whose objects shall bemapped onto the I/p & O/p ports of the PLC for remote control of the leakcheck system.

When the Software loads, it should display all the three vacuum chambers, itsinterconnection and the associated sensors & actuators with identifying legendsand provision to select the desired chamber on the page (selectable by theuser) with its status or read-outs.

The major readouts (Sensors) for operation of the chamber are one Piranigauge for rough vacuum measurement, one cold cathode gauge for highvacuum measurement, water level in the tank feeding the chiller plant, 3-thermocouples for oil temperature of diffusion pump, 3-RTDs for the watertemperature of the chilling water of diffusion pumps, position sensors of highvacuum valves (one for roughing valve, one for back-up of diffusion pump & forthe upstream of diffusion pump), current measurements for status of root &rotary vane pumps & diffusion pumps.

The major actuators (valves & relays) for operation of the chamber are solenoidoperated controlled by Solid state relays for the operation of high vacuumvalves and 3Ø relays for the supply connection to root & rotary vane pump &diffusion pump and water pump for filling the water tank.

Once the Vacuum chamber screen is loaded, the initial conditions for therelevant actuators (valves & relays) should be set by the HMI/SCADA throughPLC and the relevant sensor readings displayed in the corresponding object inthe HMI/SCADA screen. Once the default configuration is loaded and is ready,the operator should be able to start evacuation of the vacuum chamber byCLICKING the “Start Evacuation” button on the screen. This should start theautomatic evacuation of the chamber by PLC using the built-in logic. Thesequence and the checks needed are illustrated in the form of a Flow chart


34

PLC Connections for the controlling a Single Vacuum chamber

Input to PLC based on number and the data type

1 ------ Pirani gauge, 0-10 V (AG)

2 ------ Cold cathode, 0-10 V or Proprietary protocol (CC)

3 ------ High vacuum valve 1 low position (HV1 - L) (Voltage)

4 ------ High vacuum valve 1 high position (HV1 – H) (Voltage)

5, 6 7 ----- Thermocouples from diffusion pumps (TC) (0 to 200 mV)

8 ------ High vacuum valve 2 low position (HV2 – L) (Voltage)

9 ------ High vacuum valve 2 high position (HV2 – H) (Voltage)

10----- High vacuum valve of diffusion pump low position (HVAC- L)(Voltage)

11----- High vacuum valve of diffusion pump high position (HVAC – H)(Voltage)


35

Output from PLC to control elements

1 ------ 3Ø phase electro mechanical relay to diffusion pump (230V)

2 ------ 3Ø phase electro mechanical relay to root pump (415 V)

3 ------ 3Ø phase electro mechanical relay to rotary vane pump (415 V)

4 ------ Solid state relay for controlling solenoid valve of HV1 (230V)

5 ------ Solid state relay for controlling solenoid valve of HV2 (230V)

6 ------ Solid state relay for controlling solenoid valve of HVAC of diffusionpump (230V)

7 ------ 3Ø phase solid state relay to water pump (415V)

The above input and output is just shown as reference for a single vacuumchamber, depending on the mimic drawing similar CONFIGURATION has to befollowed for vacuum chamber 2 & 3.

The entire operation of vacuum chamber to be done by PLC in close loop basedon feedback mechanism and data acquisition need to be done.

The flowchart for PLC operation is as follows


36

FLOW CHART FOR VACUUM CHAMBER OPERATIONS FOR CALIBRATION AND LEAK CHECK

SELECT THE VACUUMCHAMBER

1 2 3

Read chiller plant waterlevel

Select the chiller plant1 2

Water level>specified

level

yes

Commandto open

water levelno

Command to start chiller unit

Afterselection

other shouldbe

electricallyisolated

INTERLOCK


37

FLOW CHART FOR LEAK TEST OPERATIONS

COMMAND TO START COMPRESSOR

READ COMPRESSED AIR PRESSURE

PREESURE > 6.5bar

yes

COMMAND TO START WATER PUMP

READ PUMP OUTLET PRESSURE

PREESURE > 2.8bar

yes

No

No

SELECT THE COMPRESSOR UNIT1 2

ERROR MSG WITHEXECUTION OF SHUT

DOWN SEQUENCE

TIME TAKEN > 25 MINUTES

SELECT THE WATER PUMP UNIT1 2

Afterselection

other shouldbe


Afterselection

other shouldbe


INTERLOCK

INTERLOCK


DOWN SEQUENCE



38

FLOW CHART FOR LEAK TEST OPERATIONSSELECT

RVP +ROOT -A RVP +ROOT-B

COMMAND TO OPEN ROUGHING VALVE

READ LINE AND CHAMBER VACUUM LEVEL

COMMAND TO STARTROOT-1 FOR UNIT A ROOT-2 FOR UNIT B

Vacuum level< 40mbar yes

No


DOWN SEQUENCE


Afterselection

other shouldbe


IF UNIT A IS SELECTED IF UNIT B IS SELECTED

COMMAND TO STARTRVP-1 &2 IF CH-I IS IN OPERATION

RVP-2 IF CH-II IS IN OPERATIONRVP-1 IF CH-III IS IN OPERATION

COMMAND TO STARTRVP-3IF CH-I IS IN OPERATIONRVP-3IF CH-II IS IN OPERATION

RVP-3 IF CH-III IS IN OPERATION


39

FLOW CHART FOR LEAK TEST OPERATIONSChamber Vacuum level < 1E-1 mbar

Command to open backing valve

Chamber Vacuum level < 1E-2 mbar

Command to start diffusion pump

Read diffusion pump heater temperature

Read DP cooling coil & chiller outlet temperature

Tmp < 20 degree Celsius

Yes

No


40

FLOW CHART FOR LEAK TEST OPERATIONS

Temperature > 220 degree Celsius

Command to open HAV & command to close roughing valve

Read chamber vacuum level

Vacuum level < 2x10-4 mbar

Connect MSLD and note the reading.CALIBRATION LEAK CHECK


41

DETAILED DESCRIPTION OF PLC OPERATIONS FOR VACUUM CHAMBER

In the main screen three tabs to be displayed as shown below along withmimic diagram.

Operator has to select any one chamber for operation. Once it is selectedthe PLC logic sequence will start.

Read water tank level, if level less than minimum specified level, open thewater line valve till it reads that level.

Once the level is greater than specified level, water line valve to be closedand screen should prompt for selection of chiller unit as shown below.

As the operator selects any one of the chiller plant, an interlock should beprovided for electrically isolating other plant.

After receiving the current/ voltage signal that chiller unit is in operation, onthe screen should prompt for selection of compressor unit.

As the operator selects any one of the compressor unit, an interlock shouldbe provided for electrically isolating other UNIT.

After receiving the current/ voltage signal that compressor unit is inoperation, command will go to read compressed air pressure.

Once the pressure is greater than 6.5 bar (g), on the screen two tabs to bedisplayed for selection of WATER PUMP

As the operator selects any one of the WATER PUMP, an interlock should beprovided for electrically isolating other UNIT.

Command to read water outlet pressure, pressure > 2.8 bar (g) go to nextotherwise keep on reading water outlet pressure.

If the time taken for attaining the above mentioned pressure is greater than5 minutes, an error message to be display and abort the further sequence.

VC-I VC-II VC-III

CH-I CH-2

COMP-I

WP-2WP-1

COMP-2


42

On the main display screen two tabs should be displayed for vacuum pumpselection by the operator.

Once any one of the pumping station is selected an interlock to be providedfor electrically isolating other pumps.

If unit A is selectedCommand to start RVP-1 & RVP-2 if chamber 1 is in operation and commandto open MV1 &MV2Command to start RVP-II if chamber 2 is in operation and command to openMV2.Command to start RVP-III if chamber 3 is in operation and command to openMV1.And provide interlock to electrically isolate HV8.

Command to open roughing valve.Valve no HV1- chamber 1 is in operation.Valve no HV4- chamber 2 is in operation.Valve no HV6- chamber 3 is in operation.

If unit B is selectedCommand to start RVP-3 if any of the chamber is selected for operationand command to open HV8.And provide interlock to isolate MV1 and MV2

Read line and chamber vacuum level. CHAMBER Vacuum level reads < 40 mbar, if time taken for reaching vacuum

level is greater than 35 minutes display an error message and abort theprogramme if not go to next.

If unit A is selectedCommand to start ROOT 1 for any of the chamber in operation.

If unit B is selectedCommand to start ROOT2 for any of the chamber in operation.

Read chamber vacuum level Vacuum level < 1E-1 mbar

RVP + ROOT-A RVP+ ROOT-B


43

Command to open backing valve HV2&HV3, if chamber 1 is in operation.Command to open HV5 if chamber 2 is in operation.Command to open HV7 if chamber 3 is in operation.

Read chamber vacuum level Vacuum level<1E-2 mbar, read DP cooling coil and chiller outlet temperature

otherwise keep on reading chamber vacuum level. Temperature < 20 degree Celsius command to start diffusion pump,

otherwise keep on reading DP cooling coil and chiller outlet temperature.Command to DP1&DP2 if chamber 1 is in operation.Command to DP3 if chamber 2 is in operation.Command to DP4 if chamber 3 is in operation.

Read diffusion pump heater temperature Temperature reads >220 degree Celsius, command to open HAV &

command to close roughing valve. Otherwise keep on reading diffusionpump heater temperature.

Command to open HAV1&HAV2 and command to close HV4 ifchamber 1 is in operation.Command to open HAV3 and command to close HV4 if chamber 2 is inoperation.Command to open HAV4 and command to close HV6 if chamber 1 is inoperation.

Read chamber vacuum level Vacuum level reads < 2E-4 mbar, a pop up message should be displayed

“CONNECT MSLD TO VACUUM SYSTEM, system ready for calibration andleak check. Otherwise keep on reading chamber vacuum level.

Command to open DV2 if chamber 1 is in operation.Command to open DV3 if chamber 3 is in operation.

Two tab to be displayed on the screen as

CALIBRATION LEAK CHECK


44

Once calibration radio button is pressed following page need to be displayed

CALIBRATION

RECORD CHAMBER VACUUM LEVEL:

MSLD WITH DUMMY CLOSURE:

MSLD WITH STD LEAK Qc:

MSLD WITH FLEXIBLE HOSE:

MSLD WITH VACUUM CHAMBER:

MSLD AND STD LEAK CONNNECTED TO VACUUM CHAMBER Qo:

SAVE

CALIBRATION DATE:

STD LEAK USED:

Calibration ratio R= Qc/Qo :

EDIT

1. Calibration date to be automatically generated and displayed2. Std leak used to be entered by the operator3. Chamber vacuum level to be taken from the penning gauge of the

corresponding vacuum chamber in operation.4. MSLD with dummy closure to be taken from the MSLD5. MSLD with STD leak to be taken from the MSLD once the operator connect

STD leak to the MSLD.6. MSLD with flexible hose to be taken from MSLD7. MSLD with vacuum chamber to be taken from MSLD8. MSLD and STD leak connected to vacuum chamber, to be taken from MSLD

once it is connected to vacuum chamber.9. Calibration ratio to be calculated based on Qc & Qo value.10. Once the save button is pressed full page will be saved.11. Once the edit button is pressed the entire tab will become live and data can

be recaptured once the radio button is pressed.


45

ONCE LEAK CHECK BUTTON IS PRESSED FOLLOWING PAGE NEED TO BEDISPLAYED.

LEAK CHECK

RECORD CHAMBER VACUUM LEVEL:

MSLD WITH CHAMBER WITHOUT HARDWARE PRESSURE:

MSLD WITH CHAMBER WITH HARDWARE PRESSURE Qm:

SAVE

Leak rate : Qc/Qo * Qm :

LEAK CHECK DATE :

LEAK CHECK DATE TO BE AUTOMATICALLY TAKEN FROM THE SYSTEM CHAMBER VACUUM LEVEL TO BE RECORDED FROM PENNING GAUGE. MSLD WITH CHAMBER WITHOUT HARDWARE PRSSURE TO BE TAKEN FROM

MSLD MSLD WITH CHAMBER WITH HARDWARE PRESSURE TO BE TAKEN FROM

MSLD. LEAK RATE TO BE CALCULATED BASED ON THE ABOVE MENTIONED

FORMULA. ONCE THE SAVE BUTTON IS CLICKED ENTIRE PAGE WILL BE SAVED.

EDIT


46

FLOW CHART FOR SHUT DOWN OPERATIONS

Specifications

Command to close HAV

Command to close DP pumps

Read DP pump heater TMP

TMP < 80 degree Celsius

Command to close root pump.

Command to close RVP

Command to close backing valve

Command to close water pump

Command to close compressor

Command to close chiller unit


47

Sl.NO. DESCRIPTION RECOMMENDED SUPPLIERS / MAKE

1 PLC 1) M/s Siemens2) M/s Schneider3) M/s GE4) M/s Sigmatek5) M/s Allen Bradley6) M/s B&R

2 Operator Stations 1) M/s IBM2) M/s HP3) M/s DELL4) M/s COMPAQ5) M/s ACER6) M/s Fujitsu

3 Servers 1) M/s IBM2) M/s DELL3) M/s COMPAQ4) M/s ACER5) M/s Fujitsu

4 Network Switch 1) M/s Cisco2) M/s D-Link3) M/s Allied Telesis

5 Instrumentation Rack 1) M/s Rittal2) M/s President System

6 Connectors 1) M/s Weidmuller2) M/s Harting3) M/s Phoenix

7 Ethernet Cable 1) M/s D-Link2) M/s AMP3) M/s Beldon

8 Pressure transmitter 1) Emerson Rosemount2) Yokogawa3) ABB4) Smar

Annexure -1


48

5) Fuji Electric

9 Temperaturetransmitter

1) Emerson Rosemount2) Yokogawa3) Smar4) ABB5) Fuji Electric

8 Relays 1) Phoenix2) Siemens3) Schneider4) Shradder

10 Electro Pneumaticball valves

1) Vaas automation private ltd2) L&T valve ltd3) Virgo engineers pvt ltd4) Weir bdk valves ltd5) Microfinish valves ltd

11 Electro pneumaticvacuum valve

1. VAT vacuum

2. Pfeiffer vacuum

3. Edwards vacuum

4. Agilent vacuum

5. Hind high vacuum


49

DATA BASE FOR CRYO LEAK AUTOMATION

DATA BASE STRUCTURE

LEAK CHECK DATA BASE

System table Hardware table Legend table Manifold tablePressure drop table MSLD Leak test table Vacuum Leak table

Tables requiring authorized access and updation offline of process

System table

Hardware table

Legend Table

Manifold table

Tables requiring updation during online process

Pressure drop table

MSLD Leak test table

Vacuum Leak table

ANNEXURE II


50

Structure of individual tables

System table

Unique Identifier / Autoincrement

System Name Description of system

Hardware table

UniqueIdentifier/ Autoincrement

Systemuniqueidentifier

(Fromsystemtable)

Hardware Name

Volumeofhardware

Pressure forleak

checkby

pressure drop

method

Duration forleak

checkby

pressure drop

method

Pressure forleak

checkby

MSLDdetector probemethod

Pressure forleak

checkby

vacuummethod


51

Legend table

Unique Identifier /Auto increment

Hardware name(from hardwaretable)

Legend Name Description oflegend

Manifold table

Unique Identifier / Autoincrement

Manifold Id Channel Id -1 Channel Id -2


52

Pressure drop table

MSLD Leak test table


Hardwarename(fromfront enddisplay)

HardwareID

Date

(fromfrontenddisplay)

Time

(fromfrontend

display)

Legend


leakrate


Testnumber(fromfrontenddisplay)



HardwareID

Date Time

(fromfrontend

display)

Initialpressure


Finalpressure


Duration


Testnumber


53

VACCUM LEAK TEST TABLE



HardwareID

Date Time MSLDvaluewithSTDleak,Qc

MSLD &STD leakconnectedtovacuumchamber,Qo

CalRationQc/Qo

MSLDwithchamberwith H/wpressure,Qm

Vacuumleakrate

Qc/Qo*Qm

Data to be retrieved from front end display

Request for Proposal on automation of leak check operations … · 2018. 2. 12. · Make : Pfeiffer Vacuum MODEL NO: HLT 260: HLT 560: ASM310. Request for Proposal on automation of

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