SPECIFICATION Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA) Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011 Issue: 01. Revision: 00. WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT 1 INTEGRATED AEROSTAT SURVEILLANCE SYSTEM-MEDIUM SIZE (NAKSHATRA) SPECIFICATION OF WINCH AND MOORING SYSTEM AERIAL DELIVERY RESEARCH & DEVELOPMENT ESTABLISHMENT DEFENCE RESEARCH & DEVELOPMENT ORGANISATION MINISTRY OF DEFENCE, GOVERNMENT OF INDIA P. B NO. – 51, STATION ROAD, AGRA CANTT – 282 001 Information in this document is property of Aerial Delivery Research & Development Establishment. Unless otherwise specified, no part of this document may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from Director, Aerial Delivery Research & Development Establishment, Agra.
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SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011 Issue: 01. Revision: 00.
AERIAL DELIVERY RESEARCH & DEVELOPMENT ESTABLISHMENT
DEFENCE RESEARCH & DEVELOPMENT ORGANISATION
MINISTRY OF DEFENCE, GOVERNMENT OF INDIA
P. B NO. – 51, STATION ROAD, AGRA CANTT – 282 001
Information in this document is property of Aerial Delivery Research & Development Establishment. Unless otherwise specified, no part of this document may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from Director, Aerial Delivery Research & Development Establishment, Agra.
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011 Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
2
TABLE OF CONTENTS
Chapter No. Chapter name Page no. 1.0 Introduction 3 2.0 System Description 7 3.0 System Specification/Requirements 11 4.0 Subsystem Description 21 5.0 Scope of work 58 6.0 Inspection and Acceptance Procedures 59 7.0 Painting 59 8.0 Integration, Installation and commissioning 60
9.0 Materials for Fabrication/integration/installation
60
10.0 Quality control 61 11.0 Perfection of work 62 12.0 Safety requirements 63 13.0 Tools for maintenance 64 14.0 Jigs and fixtures 64 15.0 Deliverables 64 16.0 Time schedule 65 17.0 Guarantee/Warranty 66 18.0 Product Support 66 19.0 Presentation 66 20.0 Compliance sheet 66
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011 Issue: 01. Revision: 00.
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1.0 Introduction
Winching and Mooring system is one of the major subsystems of an
Aerostat. It has two parts, one is winch, which is required for raising, lowering
& holding the balloon at a desired height, Second a mooring system on which
the balloon is anchored when not in flight. The system is required to be
fabricated for medium size of Aerostat. Mooring system must have freedom of
wind-vaning.
This system consists of a winch system, which is required for hoisting
& de-hosting of the aerostat under controlled conditions, to a desired attitude
and/or making necessary operational adjustments to the aerostat at different
altitude during flight. Mooring System is used to moor the aerostat at ground
in case of high wind conditions or maintenance / integration purpose. Mooring
is an important stage of the aerostat launch program. For the integration of
the equipment on the balloon, its maintenance and several other reasons,
aerostat needs to be brought down on the ground and moored in such a way
so as the stresses on the aerostat structure are minimal in the moored
condition.
The complete system has to be mounted on the trailer through the
slewing bearing. This slewing bearing will provide the wind vaning of the
system. However trailer will provide the relocatibility of the system. The trailer
should be provided keeping in the view that it should be compatible with the
TATA LPS 4018.
The configuration of this system is shown at figure no – 1 in Deployed
condition and figure no – 2 in transportable condition. The winch and mooring
system with balloon in moored condition and with flying condition is shown in
the figure 3 & 4 respectively.
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011 Issue: 01. Revision: 00.
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Figure 1: Winch and mooring system in deployed condition Figure 2: Winch and mooring system in transportable condition
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011 Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
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Figure 3: Winch and mooring system with balloon in moored condition
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011 Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
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Figure 4: Winch and mooring system with balloon in flying condition
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011 Issue: 01. Revision: 00.
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2.0 System Description
The winch and mooring system provides platform to hold the balloon
for the fitment of the payload to it and maintenance requirements of the
Aerostat. It is also used for launching and recovery of the balloon. The
winching system is used for inhauling and outhauling of the balloon at
required height with required speed. The various subsystems of the winch and
mooring system are shown in the system tree (figure no 05) and in the
pictorial view in figure no. 06 & 07. One similar winch and mooring system is
available with ADRDE. All the parts have been assembled together to form a
single unit from which aerostat launch, recovery, mooring, maintenance and
controlling can be done. The mooring tower along with boom, winch enclosure
and flying sheave rotates about the vertical axis passing through the center of
the main bearing. A Double capstan type hydraulic winch system is chosen for
the above configuration with spooler for uniform winding of tether. A hard
nose with nose probe and a latch assembly is chosen for mooring system.
The entire winch and mooring system will be mounted on the trailer to make
the system relocatable i.e. it will be transportable in a stowed condition. This
will be achieved by incorporating folding side arms for the close haul winches
and a foldable tower for the cradle and latch assembly. The winch assembly
and hydraulic power pack are enclosed inside a shelter (enclosure), which is
mounted over the boom. This enclose is an air-conditioned chamber. The
prime mover for towing the trailer mounted winch and mooring system is
TATA LPS 4018.
The winch and mooring system consists of following subsystems:
I) Fabricated Structure
II) Docking and tether routing units
III) Winch assemblies
IV) Hydraulic system
V) Electrical and electronic subsystem
VI) Miscellaneous subsystem
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011 Issue: 01. Revision: 00.
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Figure 5: System tree
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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Figure 6: Various subsystems of Winch and mooring system
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Figure 7: Various subsystems of Winch and mooring system
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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3.0 System Specifications/Requirements:
3.1 Brief Specification:
S. No.
Parameters Value
i Winch Type Capstan type hydraulic ii Mooring type Hard nose type, wind vanning
iii Dimension in transportable condition
As per given in the figure 8
iv Relocatibility Mounted on trailer and compatible with TATA LPS 4018
v Max. Winding/unwinding speed of main tether winch 75 m/min at 34000 N
vi Max. winding/unwinding speed of close haul/nose line winch 30 m/min at 1500O N
vii Brake holding capacity 100000 N
viii Max. winding/unwinding speed in syncro mode for all winches
30 m/min
ix Survival wind speed (when moored)
70 knots
x Operational wind speed (when parked at altitude) 50 knots
xi Operation
a) Through joystick, through lever, Manual cranking etc. b) System should also be operated through remote control panel by Radio Frequency command system
xii Stow drum Storage Capacity 1500m of tether
xiii Tether Fiber optic, power conducting, lightning braid having diameter 18±0.5 mm
xiv FORJ At winch drum xv Material Marine grade anti-corrosive steel xvi Data logging facility Record to store the various data
xvii Storage Rugged storage device should be provided for storage of data for minimum 15 Days
xviii EMI/EMC All electrical/electronic equipments must be EMI/EMC protected
xix Portability of data It should be possible to transfer data from archive media into suitable removable hard discs/CDs/zip drives etc.
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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Fig 8: Loads coming on Winch and Mooring Platform
12.7 m
12.9 m F2
F1
38 m
12.7 m
18.8 m
23.6 m
19.7 m
C P C G
Confluence Point
W
C B F3
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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These dimensions are indicative value only the final dimension will be finalised during design review.
Figure 9: Winch and mooring system dimension in folded condition
Height =
4m
Length = 14m Width = 2.5m
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3.2 Detail Specification:
i) The Winch and mooring system is required to hold the medium size
Aerostat. The brief dimension of the Aerostat has been given at the
Figure no. 9.
ii) Mooring structure should be made in foldable modules to enhance
the ease in transportation. The dimension of the winch and mooring
system in the folded condition should not be more than 14 m
(length) X 2.5 m (width) X 3.7m (height). The folding/unfolding
operation should be mechanised (preferably hydraulically/electro-
mechanical). The suitable locking arrangements should be provided
during transportation and actual operational condition.
iii) The winch is required to be capstan type with level winding
arrangement (spooler) for uniform winding of tether, Single tether
with hydraulic as well as electronic control.
iv) Mooring system should be turn table type, hard nose with nose
cradle and a latch assembly. Mooring system must have freedom of
wind - vaning.
v) A pedestal hydraulic power drive is required to orient the winch and
mooring system as per the requirement of the Aerostat.
vi) The winch should be capable of hoisting and de hoisting the
Aerostat at a tether tension of 34000 N at winding speed of 75
m/min.
vii) The speed of the winch and mooring system should be varied from
0 to 75 m/min.
viii) The Nose line winch and close haul winches should be designed to
operate at 30 m/min at a load of 15000 N. However it should
withstand a load of 30000 N.
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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ix) perating limits: The system should be capable of withstanding the
following conditions in different orientations:
(a) 70 Knots (36 m/s) wind speed when the balloon is moored on
the structure and faces into the wind.
(b) Side force corresponding to 20 knots (10.29 m/s) wind speed,
which acts in case the bearing fails to rotate.
x) Winch and mooring system is capable of withstanding 100000 N
acting at the flying sheave. The structure, flying sheave, Pulleys etc
should be design to withstand that much of load.
xi) The whole structure should able to rotate freely at a torque value
1200 Nm or less.
xii) The brake holding capacity of the winch system should be 100 kN.
It means that when this much of load will come on the tether, the
tether should not unwind itself from the winding drum.
xiii) All Aerostat program e.g. launching, recovery, mooring, controlling
etc can be done should be done at single place i.e. at the operator
cabin inside the winch enclosure. Provision should be made so that
operator can communicate with other crew members.
xiv) A provision should be made in the cradle and latch assembly for
automatic release of nose probe from the cradle.
xv) Provision should be made to digital display and record the various
parameters e.g. winding/unwinding speed of the main winch, tether
tension value before and after the capstan, tension value of the
nose line and close haul lines, Tether released out from the drum
and tether storage length, Temperature of hydraulic oil, level of the
hydraulic oil in the reservoir etc.
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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xvi) Data logging facility should be provided to record the data for
minimum Fifteen (15) days. A rugged storage data device should be
provided along with the system.
xvii) A portable data storage and analysis device and a online rugged
data streaming device should also be provided for analysis of the
store data.
xviii) All operation should be done by joystick provided at operator cabin.
However provision should also be made to operate the system
through hydraulic lever through Proportional control valve for
redundancy. In case power failure the manual operation should also
be provided.
xix) The operator can also operate the system form the ground through
remote/operator panel, instead of sitting in the operating cabin if the
need arises. A Radio Frequency link in this regard should also be
available.
xx) Pneumatic Power Pack and airbag is controlled and operated from
the controller cabin.
xxi) The winch should be automatically stop the operation when the
seventh (7th) turn of the lowest layer of the tether remains on the
stow drum.
xxii) Synchronization of two close haul winches, nose line winch,
capstan and stow drum will be made. This means capstan, stow
drum, two close haul winch and nose line winch should be operated
simultaneously at same speed. The maximum winding/unwinding
speed in this case will be 30 m/min
xxiii) The winch and mooring should be suitable for inflation and deflation
of the Aerostat when moored at the mooring structure.
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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xxiv) All the items should be used for the fabrication of the winch and
mooring system should be of flameproof & explosion proof quality.
xxv) All fasteners e.g. nuts and bolts, studs etc used in the assembly
should be of suitable strength and protection with corrosion.
xxvi) The system should be transportable by road in folded conditions.
xxvii) Access ladder should be provided to access the operator cabin and
the roof of the winch enclosure. Access ladder should have proper
side and overhead protection.
xxviii) The hydraulic oil shall be selected as per following temperature
range. Storage temperature –200 C to +700 C, Operating
temperature –100 C to +550 C
xxix) Cradle is able to tilt +1250 and – 450 from the horizontal
xxx) A slewing bearing of suitable capacity is to be provided which can
withstand radial, axial and tilting moments.
xxxi) Material to be used for fabrication of the structure is marine grade
anti-corrosive steel or equivalent.
xxxii) One sets of Slip rigs integrated with FORJ are provided to supply
the power to the prime mover as well as two way transfer the data
from the airborne to the ground. Such slip ring and FORJ is to be
provided at the stow drum to provide power and data to the tether.
The Power slip ring with central hole is to be provided at the
pedestal to transfer the power from the main supply to the rotating
winch and mooring system.
xxxiii) The trailer should be suitably selected/designed to house the
system. It should also be able to travel in desert terrain and
compatible with the prime mover TATA LPS 4018.
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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xxxiv) Provision should be made to grounding the lightening braid of the
tether.
xxxv) The winch enclosure should be properly covered so that the winch
enclosure is protected from dust, rain etc. To reduce the heat load
on the air conditioner the panels of the cover should be made of
insulating material.
xxxvi) The critical components of the system should sustain the following
environmental conditions:
a) Ambient temperature
Operating temperature range: –100 C to +550 C
Storage temperature range: –200 C to +700 C
b) Humidity: up to 95% at +40oC, non-condensing conditions.
4. Tether Details : Diameter : 18+0.5 mm Total Length : 1500 m Tether weight : 400 g/m (estimated)
5. Drum Dimension:
Flat Drum Diameter: 600 mm Drum Flange Diameter : 1200 mm Flange - Flange inner offset : Min. 1230 mm
Max. 1235 mm Drum Slot width (for cable termination) : 45 mm
6. Drum storage Capacity 1500 m
7. Drum Shafts : Flanged hollow shafts ( 2 Nos.) Shaft Inner Diameters : 150 mm, each Shaft Bolted to Drum
8. Input power From Hydraulic motor 9. Design Parameters
Maximum cable Speed: Maximum Tension:
75 m/min (corresponding to 34000 N at Capstan) 15000 N
10. Gearbox : 1 No. integrated gearbox *Gearbox Efficiency > 85 % to be ensured *Manual operation: Should function with hydraulic
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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motor braked *Manual clutch engagement / disengagement *Easy access to all manual handles from outside *Integral Multi-disc brake units *Brake units to be compact and optimally located
11. Spooler :
*Light weight pulley with vertical axis, mounted on carriage with Diamond Screw & Pawl Arrangement and Hollow guide shafts (2 Nos.) *Pulley Diameter : 600 mm *Pulley width to cater for spooling on 1st and last layers
12. Features:
*Protective covers to be provided where necessary *All sharp corners to be rounded of in tether path *All manual operations to be possible from spooler side *System weight optimization to be enforced during design
Note : This specification sheet are for reference o nly.
4.3.3 Close haul & nose line winches
The two Close Haul winches are used to hold the Aerostat from
the port and starboard side of the balloon. The Close Haul winches are
mounted on two swing frames that can be folded during transportation.
The construction of the Nose Line winch is identical to the close haul
winches. The Nose Line Winch is located below the mooring tower and
is used for guiding the Aerostat nose probe into the Cradle for docking
through the nose line cable. These drums should have capacity to store
80 m of mooring cable and are driven by a hydraulic motor via a
reduction gearbox. The operation of these winches is controlled from
the Operator Control Desk and they can be selectively synchronized
with all other winch. These winches are fitted with an integral fail-safe
brake that prevents winch slippage when not in operation. Provision
should be made for a manual over ride for operation using a hand
pump to drive the close haul winch motor.
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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Fig. 24: Close haul/Nose line winch
Specification Sheet For Close Haul/Nose line Winch
1. Application: Storage and handling of close haul lines
2. Quantity: 3 nos. 3. Configuration: Compact & Light weight Design 4. Close Haul Line Details:
(ADRDE will supply) Diameter : 12 mm Total Length to be stowed: 80 m Material : Nylon
5. Drum Dimension: Cylindrical Drum without grooves Drum Diameter: 300 mm Flange Diameter : 450 mm Flange Slot width (for line termination) : 20 mm
6. Design Parameters Maximum cable Speed: Maximum Tension: Brake load:
30 m/min 12000 N 24000 N
7. Weight: minimum
Note: These specification sheets are for reference only.
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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4.4 Hydraulic System
Hydraulic system consists of
i) Electric motor
ii) Hydraulic pump
iii) Hydraulic motor and actuator,
iv) Proportional Valves Assembly
v) Oil tank
vi) Oil cooler system
vii) Various Valves & Accessories.
The hydraulic drives are required to drive capstan, stow drum, two
close haul winches, a nose line winch, tower actuator, pedestal drive and
cradle actuator. The drives to these actuators should come from a single
hydraulic power pack. This hydraulic power pack is integrated with the
proportional direction control valve and counterbalance valve. High response
shock and cavitation valve should also be incorporated to absorb high shocks
when the joystick will be released and Capstan brakes immediately.
Additionally one relief valve should be provided in every actuator circuit. The
system should be designed at Maximum system pressure 350 bar and
maximum flow of 300 lpm.
All the operation of the actuator is through Joystick & through hydraulic
lever which is placed at the control cabin. Some of the actuator like stow drum
and capstan can also be operated through manual cranking. The reference
hydraulic circuit which may be used for this operation is given in figure no.25.
The bill of material and their make is also given in table no.1. The given
circuit and bill of materials are only for the refe rence, the actual circuit
and bill of material fill be finalized during the d esign and its review and
vetted by DIRECTOR ADRDE or his authorized represen tative. The entire
system should be designed and configured by using high quality
Commercially Off The Shelf (COTS) equipment.
SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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SPECIFICATION Integrated Aerostat Surveillance System -Medium Size ( NAKSHATRA)
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Table 1 Sl.
No. Part description
Specification Make
1. Electric Motor 3-�, 415V, 75 kW, Qty: 2no. Crompton Greaves
or equivalent
2. Hydraulic Pump
Variable Displacement, 100cc/rev,
HP limiter with load sensing and
pressure compensator, Qty: 2no
Rexroth or
equivalent
3. Heater 12 kW, 3-�, 230 V A/C Elmec or
Equivalent
4. Hydraulic
Reservoir
Capacity of 1000 ltrs with access
door for cleaning Reputed make
5. Oil level Gauge For giving information of oil level Stauff or
equivalent
6. Level switch For switching operation between
two oil level
Monitor India or
equivalent
7. Temperature
sensor Range -500 C to +2500C Wika or equivalent
8. Air breather 2µm rating Argo or equivalent
9. Direction control
valve Various sizes
Rexroth or
equivalent
10. Check Valve
Capacity Quantity
10 lpm 03 no.
22.5 lpm 07 no.
40 lpm 04 no.
70 lpm 12 no.
120 lpm 01 no.
135 lpm 03 no.
180 lpm 01 no.
280 lpm 01 no.
Rexroth or
equivalent
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11. Pressure line
filter 12 µm size filter with clog indicator Pall or equivalent
12. Return line filter 5 µm size filter with clog indicator Pall or equivalent
13. Pressure relief
Valve
Capacity Quantity
95 lpm 03 no.
320 lpm 01 no.
Rexroth or
equivalent
14. Pressure
reducing valve
With various pressure setting and
sizes
Rexroth or
equivalent
15. Pressure Gauge Range 0 to 450 bar Forbes Marshal or
equivalent
16. Proportional
valve
180 lpm , 115 lpm (3 valve module)
and 180lpm (4valve module)
Rexroth or
equivalent
17. Shuttle Valve
Pressure Capacity Quantity
315 bar 30 lpm 01 no.
350 bar 10 lpm 05 no.
Rexroth or
equivalent
18.
Counterbalance
valve (Air
vented)
Capacity Quantity
60 lpm 06 no.
120 lpm 08 no.
480 lpm 02 no.
Rexroth or
equivalent
19. Shut-off valve
Input Pressure: 350 bar
Capacity: 80 lpm
Quantity: 01 no.
Rexroth or
equivalent
20. Needle Valve
Input Pressure: 350 bar
Capacity: 40 lpm
Quantity: 02 no.
Rexroth or
equivalent
21. Ball Valve Size: 1”, 2”, 3” Rexroth or
equivalent
22. Hydraulic Motor
625 cc/rev, 1800 rpm, Qty: 03 no.
468 cc/rev,1800 rpm, Qty: 01 no.
1130 cc/rev, 110 rpm, Qty: 01 no
2857 cc/rev, 63 rpm, Qty: 01 no
Rexroth or
equivalent
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23. Hydraulic
Cylinder
Bore Dia: 140mm
Rod Dia: 90mm
Stroke: 1150mm
Rexroth or
equivalent
24. Oil Cooler Unit Cooling capacity 45 kW Emmegi or
equivalent
25. Rotary Actuator Bore 50.8 mm, Rotation 1200, both
direction rotation
Rexroth or
equivalent
26.
High Response
Shock and
Cavitation Valve
To be suitably selected Rexroth, Parker or
equivalent
27. Hydraulic Hose Various sizes, to be suitably
selected
Parker or
equivalent
28. Fitting Weld nipple type of Parker soft
seal
Parker or
equivalent
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4.5 Electrical and Electronic Sub-Systems
Electrical and electronic sub-system consists of control desk master
controller (PLC based), PLC,HMI and SCADA software, MCC Panel, winch
power panel, encoders & sensors, operator display with HMI software,
operator control desk, power slip ring and FORJ assembly, cradle camera and
accessories. PLC based master controller controls and monitors the winch
operation. Winch power panel supplies power to all platform equipments. To
measure, display and record of various parameters of the winch and mooring
system encoders and sensors are used. Power slip ring transfers the power
between stationery and rotary parts and FORJ will transfer the data from the
rotary to stationary parts and vice versa. Data storage facility should also be
provided to store the various data for a period of at least one week. The main
subsystem is described in succeeding paragraph.
4.5.1 Operator Cabin and Control Panel:
A control console will be provided with a joystick for various winch
control and a display for viewing operating parameters. It should be
ergonomically designed and should have push button/touch pad, selector
switches and indicating lamp for control and monitor of the system. It should
also have indicators to indicate the winding and unwinding position of main
winch, close haul winch, nose line winch and status of electrical and hydraulic
subsystems. The operator cabin consists of following:
(a) Main controller:
It would provide controls for operating the motors and indicate system
status.
(i) Should consists of a Human Machine Interface (MIL grade flat
Panel TFT display and keyboard and touchpad )
(ii) Should operate on 230 V AC, 50 Hz
(iii) A back-up power supply should be provided to operate the
system for at least 30 min.
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(iv) CPU having state of art processor and motherboard with PC
slots (4 minimum) for analog/digital input/output.
(v) Should be accompanied by a software for co figurate the system
and to monitor system status.
(vi) System should have at least 500 GB hard disk.
(vii) Should have soft switches as listed below
a. HOME
b. ERROR LOG
c. PARAMETER SET
d. ALARM
(viii) Should also have lighted push buttons for controlling winch
independently & LED indicator for indicating status of winch.
(ix) Graphics Terminal: The graphics terminal is configured to
display the status of system. Various soft switches are activated
via feather touch switches to the left of the display. The various
soft switches are listed below
(a) HOME: Returns the display to the HOME screen.
(b) ERROR LOG: Display the error log, which maintains the
record of occurrences of all the errors in the system for a
period of 30 days. The information displayed on the screen
should be recorded for offline viewing. The field tabulated in
the error log are:
� Serial number
� Error Description
� Time of occurrence
� Time when the error was accepted (Alarm Reset Time)
� Time when error was corrected
(c) PARAMETER SET: Display screen where control
parameters can be set:
� Serial number
� Parameter
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� Setting of the parameter
� New value for setting
� Restore original value
� Restore to default value
(d) ALARM ACCEPT: Key to acknowledge all identified
alarms and mute speaker.
The reference detail of PLC is as follows:
The entire Winch and Mooring system is realized around a
Programmable Logic Controller The PLC is divided into the following
MODULES:
i. Power Supply Module: CPS
ii. Central Processing Unit module: CPU
iii. 64 Channel Digital I/P Module: DI1
iv. 64 Channel Digital O/P Module: DO1
v. 8 Channel Analog I/P module: AI1
vi. 8 Channel Analog O/P module: AO1
vii. 2 Channel Counter module:CMT1
viii. 4 Channel Counter module: CMT2
ix. Spare Channel
x. Spare channel
xi. Spare channel
The Ladder Logic Software should be used for the PLC is PL7-
pro or higher version or equivalent software. The Human Machine Interface
(HMI) Software for the operating system (OS1) should be Citect or equivalent
having minimum 500 tags.
The PLC controls the following Digital Input/ Output elements of Winch
and Mooring system:
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Central Processing unit with Ethernet Port (Slot 1)
Analog Input Port
Analog Output Port
Feedback/ Acknowledgement
Central Processing unit with Ethernet Port
Feedback/ Acknowledgement
Counter Module 2 CH
Counter Module 4 CH
Capstan Stow drum
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Main purpose of this panel is to control the operation of the
motors and provide a means of protecting the motors under such fault
conditions as main motor winding overheat, single phasing, sustained
overloads and stalling. Above information related to motor condition
should be displayed in the main control panel.
(c) Encoders and load cell:
These are sensors used for sensing the various signals such as
position of the paid out length of cable or tether so that speed of paying
out of the length paid out can be calculated and number of other
parameters also.
Load cell are used to measure the tether tension before and
after the capstan.The Specification of the load cells are:
Data sheet for High tension load cell
1. Application Measurement of load in High tension side of
Capstan
2. Load Range 0 to 50000 N
3. Safe load limit 200% of full Scale Reading
4. Protection class IP 65
Data sheet for Low tension load cell
1. Application Measurement of load in High tension side of
Capstan
2. Load Range 0 to 15000 N
3. Safe load limit 200% of full Scale Reading
4. Protection class IP 65
(d) Slip rings and FORJ:
The slip ring and FORJ hybrid assembly to be fitted at the stow drum
however only slip ring with 50mm central hole is to be fitted at the
pedestal.
Technical Specifications of HYBRID FORJ Assembly at Stow Drum
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i. Optical Details
� Numbers of optical channel : 06, Single Mode (SM)
� Wave length window (λ) : 1310 – 1550 nm
� Insertion loss : ≤ 3.0 dB
� Connector/Adaptor : ST preferably
ii. Electrical Slip rings
Sl. No. Application Nos. of rings Current Rating Voltage rating Material 1. Power 03
02 15A 40A
1000V 1000V
Silver plated copper Silver plated copper
2. Lightning current drainage
01 Slip ring should be capable of passing 100KA current for time duration of 500µsec.
3. Adaptor 01 A electrical Mil grade adaptor to be provided to meet above requirement.
iii. Mechanical Details:
� Material : Aircraft Al (ASTM B 221) preferably � Rotation of power or data signal : 360° continuous � Weight : < 12 kg � Dimensions : Length 400± 10mm, Ø 200 ± 5 mm
iv. Environmental Details: � Environmental protection : IP 65 � Temperature range Operational : -10° to + 55° c
Storage : -20° to + 70° c � Vibration : Mil-std-167-1 ship vibration
v. Quantity: � Quantity required : 02 Nos.(keeping 01 as spare) Make: M/s Princetel Inc., NJ, USA
Figure 25: Drawing of Hybrid slip ring and
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Specification of the slip ring at the Pedestal
The above specification is for reference only.
(e) 3 –� Automatic voltage controller (8 kVA):
3 –� Automatic voltage controller is required to maintain 415 V
(phase to Phase) at airborne end when power supply of 8 kVA is feed
through 1500 m length of tether. A suitable automatic voltage controller
is required to made to suit this requirement.
1. Make Schleifring and apparatebau GmbH, Germany or
equivalent
2. Power Rating 250 kVA
3. Channel 11, One channel is dedicated for grounding the
lightening current of 100 kA for time duration of
500µsec, one channel is used for taking the data out
and giving command when remote operation is required
4. Current rating 600 A (min)
5. Voltage rating 415 ± 15 v
6. Central hole
diameter
50 mm
7. Protection class IP 65
8. Temperature range Operational Storage
-10° to + 55° c -20° to + 70° c
9. Vibration Mil-std-167-1 ship vibration
10. Adaptor A electrical Mil grade adaptor to be provided to meet above requirement.
11. Frequency 50 Hz
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(f) Portable Rugged Online data steaming and data s torage &
analysis device:
A portable rugged online data streaming device and a portable
data storage and analysis device should be provided with the system
for analysis and data back up at the trial site. Each of one number is
required.
The rugged portable online data streaming device should have
MIL grade components and of reputed make. The some of the
10. Low tension sensor assembly 1 no. 11. Air bags 1 set 12. Pneumatic system 1 set 13. Pressure line filter 1 no. 14. Return line filter 1 no. 15. Hydraulic Power pack (same used in the
winch and mooring system for medium size aerostat) with all its accessories, valves, proportional valves, Hydraulic Pump, Hydraulic motors, Hydraulic cylinder for mooring tower, Rotary actuator, oil cooler unit etc.
1 set
16. Hydraulic fittings 1 Set 17. Hydraulic Seals 1 Set 18. Hydraulic hose 1 set 19. Tyre with tube (besides 2 tyre-tube
provided with trailer) 4 no.
20. Access ladder for access to the control cabin(It should have proper side and overhead protection)
1 no.
21. Access ladder for access the roof of the winch enclosure(it should have proper side and overhead protection)
1 no.
Note: All the items should be packed nicely in such a way that they should fulfil all the environmental as well as transportation condition mentioned in the specification
LIST OF SPARES (Annexure – II)
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Sl. No. Scope of work Vendor Compliance
1 Design of whole system based on specification including FEM analysis of the system.
2 Preparation of Configuration Document, Preliminary Design Report (PDR), Critical Design Report (CDR) etc.
3 Review of the design by experts to be nominated by ADRDE.
4 Preparation of manufacturing drawings of all the systems and components including assembly drawing in AUTOCAD and 3D modelling duly approved by ADRDE.
5 Review of acceptance Test Procedure (ATP) based on draft ATP provided by ADRDE.
6 Preparation of QAP and WPS(Welding Procedure Specification) Document.
7 Fabrication of the complete system
8 Testing of sub-assemblies of the system as per ATP at firm’s premises.
9 Integration, installation and commissioning of whole system at ADRDE, Agra or place provided by ADRDE, Agra.
10 Fabrication of test jigs and fixtures required in manufacturing and testing.
11 Acceptance Testing as per ATP.
12 Preparation of Test Report(including stage inspection report)
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Sl. No. Specification Vendor Compliance
1 The Winch and mooring system is required to hold the medium size Aerostat.
2
Mooring structure should be made in foldable modules to enhance the ease in transportation. The dimension of the winch and mooring system in the folded condition should not be more than 12 m (length) X 2.5 m (width) X 3.7m (height). The folding/unfolding operation should be mechanised (preferably hydraulically/electro-mechanical). The suitable locking arrangements should be provided during transportation and actual operational condition.
3 The winch is required to be capstan type with level winding arrangement (spooler) for uniform winding of tether, Single tether with hydraulic as well as electronic control.
4 Mooring system should be turn table type, hard nose with nose cradle and a latch assembly. Mooring system must have freedom of wind - vaning.
5 A pedestal hydraulic power drive is required to orient the winch and mooring system as per the requirement of the Aerostat.
6 The winch should be capable of hoisting and de hoisting the Aerostat at a tether tension of 34000 N at winding speed of 75 m/min.
7 The speed of the winch and mooring system should be varied from 0 to 75 m/min.
8 The Nose line winch and close haul winches should be designed to operate at 30 m/min at a load of 15000 N. However it should withstand a load of 30000 N.
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Sl. No.
Specification
Vendor Compliance
9
Operating limits: The system should be capable of withstanding the following conditions in different orientations: (a) 70 Knots (36 m/s) wind speed when the balloon is moored on the structure and faces into the wind. (b) Side force corresponding to 20 knots (10.29 m/s) wind speed, which acts in case the bearing fails to rotate.
10 Winch and mooring system is capable of withstanding 90000 N acting at the flying sheave. The structure, flying sheave, Pulleys etc should be design to withstand that much of load.
11 The whole structure should able to rotate freely at a torque value 1200 Nm or less.
12 The break holding capacity of the winch system should be 90000 N. It means that when this much of load will come on the tether, the tether should not unwind itself from the winding drum.
13 All Aerostat program e.g. launching, recovery, mooring, controlling etc can be done should be done at single place i.e. at the operator cabin inside the winch enclosure. Provision should be made so that operator can communicate with other crew members.
14 A provision should be made in the cradle and latch assembly for automatic release of nose probe from the cradle.
15
Provision should be made to digital display and record the various parameters e.g. winding/unwinding speed of the main winch, tether tension value before and after the capstan, tension value of the nose line and close haul lines, Tether released out from the drum and tether storage length, Temperature of hydraulic oil, level of the hydraulic oil in the reservoir etc.
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Sl. No. Specification Vendor Compliance
16 Data logging facility should be provided to record the data for minimum Fifteen (15) days. A rugged storage data device should be provided along with the system.
17 A portable data storage and analysis device and a online rugged data streaming device should also be provided for analysis of the store data.
18 All operation should be done by joystick provided at operator cabin. However provision should also be made to operate the system through hydraulic lever through PVG for redundancy. In case power failure the manual operation should also be provided.
19 The operator can also operate the system form the ground through remote/operator panel, instead of sitting in the operating cabin if the need arises. A Radio Frequency link in this regard should also be available.
20 Pneumatic Power Pack and airbag is controlled and operated from the controller cabin.
21 The winch should be automatically stop the operation when the seventh (7th) turn of the lowest layer of the tether remains on the stow drum.
22 Synchronization of two close haul winches, nose line winch, capstan and stow drum will be made. This means capstan, stow drum, two close haul winch and nose line winch should be operated simultaneously at same speed. The maximum winding/unwinding speed in this case will be 30 m/min
23 The winch and mooring should be suitable for inflation and deflation of the Aerostat when moored at the mooring structure.
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Sl. No. Specification Vendor Compliance
24 All the items should be used for the fabrication of the winch and mooring system should be of flameproof & explosion proof quality.
25 All fasteners e.g. nuts and bolts, studs etc used in the assembly should be of suitable strength and protection with corrosion.
26 The system should be transportable by road in folded conditions.
27 Access ladder should be provided to access the operator cabin and the roof of the winch enclosure. Access ladder should have proper side and overhead protection.
28 The hydraulic oil shall be selected as per following temperature range. Storage temperature –200 C to +700 C, Operating temperature –100 C to +550 C
29 Cradle is able to tilt +1250 and – 450 from the horizontal
30 A slewing bearing of suitable capacity is to be provided which can withstand radial, axial and tilting moments.
31 Material to be used for fabrication of the structure is marine grade anti-corrosive steel.
32
One sets of Slip rigs integrated with FORJ are provided to supply the power to the prime mover as well as two way transfer the data from the airborne to the ground. Such slip ring and FORJ is to be provided at the stow drum to provide power and data to the tether. The Power slip ring with central hole is to be provided at the pedestal to transfer the power from the main supply to the rotating winch and mooring system.
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Sl. No. Specification Vendor Compliance
33 The trailer should be suitably selected/designed to house the system as well as compatible with the prime mover TATA LPS 4018.
34 Provision should be made to grounding the lightening braid of the tether.
35 The winch enclosure should be properly covered so that the winch enclosure is protected from dust, rain etc. To reduce the heat load on the air conditioner the panels of the cover should be made of insulating material.
36
The critical components of the system should sustain the following environmental conditions:
a) Ambient temperature
Operating temperature range: –100 C to +550 C
Storage temperature range: –200 C to +700 C
b) Humidity: up to 95% at +40oC, non-condensing conditions.
c) Altitude up to 3350 m from AMSL
d) Rain intensity (IS: 9000 part 16, Static pressure – 100 ± 15 kpa, 4 shower used at an angle of 450 for 01 hour duration).
e) Salinity (IS: 8252 part 10 Clause 4.2.2)
f) Dust as encountered in desert areas (IS: 9000 part 12, Temperature 40 ± 30C, relative humidity 40% steam of dust laden air, dust concentration less than 10 ± 3 g for a duration one hour).
g) Fungus growth as encountered in tropical climates (not encountered in mechanical components).
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Sl. No. Specification Vendor Compliance
37 The system should also be designed to cater the various load cases given in the specification at point no 3.2(xxxvii).
38 Inspection will be carried out by the Director ADRDE, Agra or his authorized representative and will be carried out in stages for raw materials, machined components, assembled components and bought out components.
39 Painting as per point no.7.0 of the specification
40 Adequate internal protection should be provided for hollow structural component sections.
41 Integration, Installation and commissioning as per point no. 8.0 of specification
42 Materials for Fabrication/Integration/installation areas per point no.9.0 of specification
43 Quality control should be as per point no. 10.0 of specification.
44 Quality control for welding should be as per point no. 10.1 of specification.
45 Perfection of Work should be as per point no. 11.0 of specification.
46 Safety requirements should be as per point no. 12.0 of specification.
47 Warranty of the system for 2 years.
48 Delivery Period (18 months after placement of Supply order)
49 Product support (AMC)( 3 years after completion of warranty period).
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Sl. No. Deliverable Vendor Compliance
1 A complete set of detailed manufacturing drawings (in 3D and 2D) of every supplied component along with assembly drawing in both hard as well as soft form.
2 Complete Design Report i.e. Configuration document, Preliminary Design Report (PDR), Critical Design Report (CDR) (including FEM Analysis report) in both hard as well as soft (in solid model) form. Document should be given in doc format.
3 QAP and WPS Document in both hard as well as soft (in solid model) form. Document should be given in doc format.
4 One set of fabricated Winch and Mooring System along with Trailer and spares. List of spares is attached as Annexure -II.
5 Schedule of spare parts with proper part nos. and source of supply and portable rate of consumption.
6 List of all brought out items with their test certificates.
7 System description, Operational, maintenance and repair/trouble shooting manuals.
8 Inspection and test reports of all components as well as the assembly.
9 Compliance report of the Acceptance test of the winch and mooring system.
10 Part list, part specification with literatures of all components. The catalogue and data sheet of all brought out item.
11 Drawings of hydraulic circuit and plumbing and bill of materials.
12 The winch and mooring should be suitable for inflation and deflation of the Aerostat when moored at the mooring structure. Fixtures for this, if any, are to be provided by the supplier.
13 Recommended spares for two years maintenance shall be supplied.
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Sl. No. Deliverable Vendor Compliance
14 Spare kit as recommended by manufacturer for all hydraulic components/ control valves and accessories used in the system shall be supplied.
15 Hydraulic hoses, tubes, end fittings connectors etc. required for two years of maintenance of the system are to be supplied.
16 Access ladders
17 Warranty certificate of the complete winch and mooring system.
18
Electronics deliverable as per following:
(i) Master controller
(ii) System Software with their licenses (iii) Console with HMI, CPU (iv) Feedback Sensors (v) Operator desk with SBC and operator dialog terminal and push buttons and levers
(vi) Networking cable and associated hardware
(vii) MCC Panel
(viii) Slip rings (one of 8kVA rating other 250 kVA rating)
(ix) Hybrid FORJ (2 no. one for the stow drum other for spare)
(x) 3 –ϕ Automatic voltage controller (8 kVA)
(xi) Portable rugged data streaming device
(xii) Portable data storage and analysis device
(xiii) Back up supply
(xiv) Communication system for maintenance crew and operator
(xv) Engineering services
(xvi) Commissioning services
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Sl. No. Task Questionnaires Vendor comment
1 Designing : Design of whole system based on specification including FEM analysis of the structure
(i) Whether firm has designed trailer mounted system of about 30 Ton weight in the past. Please furnish details in brief.
(ii) Whether firm has independent design office and design team if yes, please specify the following.
(a) How many designers are working in their design team.
(b) What are different software design tools are available with the firm. The details of workstation/licenses of the computing/analysis software (IDEAS/ANSYS/UNIGRAPHICS/Pro-E/SOLIDWORKS) etc. Vender should have at least 6 licenses.
(c) Has FEM analysis has been carried out on 30 Ton or more weight class structure in the past. Please furnish details in brief.
(d) Has the firm have the experience in designing & fabricating the winch system in the past of about 3.5 Ton tension in the rope or more.
(e) Whether the firm has experience in designing & fabricating of Hydraulic system for circuits of 300 bar and 300 lpm or more.
QUESTIONNAIRES (ANNEXURE – IV)
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(iii) Whether the firm has supplied electronic/ electrical system with PLC/SBC based in the past. Please provide details.
(iv) Whether the firm has experience in integrating multidisciplinary system in the past.
S. No. Task Questionnaires Vendor comment
2
Fabrication: (i) Whether the firm has an overhead crane of 20 T capacity at 12 m height or more.
Fabrication of winch and mooring system
(ii) Whether the firm has 40 x 40 m area (approx) for fabricating and assembly of the mooring structure.
(iii) Whether the firm has TIG and MIG welding plants please specified the number.
(iv) Please specified how many welder are approved for TIG &MIG welding procedures from competent authority.
(v) Please specify, whether firm have executed any work related to large structure in the past.
(vi) Please specify whether the firm carried out EMI/EMC and environmental testing on electrical/electronics equipment in the past.
(vii) Please specify that the following machines are available with the firm:
General purpose m/c (Qty)
(a) Power hacksaw
(b) Lathe (specify the capacity and quantity)
(c) Milling m/c (specify the capacity and quantity)
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(d) JIG boring m/c (specify the capacity and quantity)
(e) Surface grinder m/c (specify the capacity and quantity)
(f) Cylindrical grinder m/c (specify the capacity and quantity)
(g) Any other m/c (specify name, capacity and quantity)
Special Machines
(a) CNC machine centre
(b) CNC lathe machine
(c) CNC milling m/c
(d) Spline cutting machine
(e) Tool room machine for making jigs and fixtures.
(viii) Please specify that following material handling equipments are available with the firm.
(i) Hard flooring on which the system can be assembled. Specify the Area.
(ii) Independent QA team & inspection lab. Knowledge of test procedures.
(iii) Measuring instruments like
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(a) Vernior Calliper (For measuring of 1 m length)
(b) Micro meter 500 mm
(c) 3D Co-ordinate m/c
(d) Micro examination m/c for materials
(e) Capable of measuring inspection jig for 18 m structure length.
(iv) Hydraulic circuit test facility like:
(a) Leakage test
(b) High pressure test (500 bar or more)
(c) Other Hydraulic test and maintenance facility. Please specify
(v) The sufficient power available for operating 150 kW motor and alternate power source like DG Set (250 KVA)
(vi) Load test facility & its measurement capability through strain gauge method using software like lab view etc.
(vii) Material test lab facilities like:
(a) Spectrometer
(b) Chemical composition
(c) UTM
(d) Hardeners tester etc
(e) Radiography test
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(f) Megnaflax testing etc.
(viii) Load test facility on mooring tower at different angle and its measurements
4
Execution of Govt. order in the past.
(i) Firm should specify the value of a single supply order received from the government, department of a system which they have successfully executed in the specified time in the past. Please furnish the details.
(ii) Firm should specify the financial strength and its turnover should be more than 75 crores in the last year.