Specification Adrde 210212

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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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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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

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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




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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.




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Figure 1: Winch and mooring system in deployed condition Figure 2: Winch and mooring system in transportable condition




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Figure 3: Winch and mooring system with balloon in moored condition




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Figure 4: Winch and mooring system with balloon in flying condition




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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




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Figure 5: System tree




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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




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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.




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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




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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.




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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.




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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.




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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.




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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.

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 ± 3 0C, 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).

xxxvii) The various input data for system are as follows*

a. Aerostat Parameters

Aerostat Volume : 3500 cum

Maximum Buoyant Force : 32570 N

Aerostat Weight : 1492 kg + 300 kg payload

Offset of Confluence Point : 12.9 m, from Nose

: 12.7 m, below from central axis

* These data are indicative only however actual value will be finalised at the time of design review




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Offset of CP : 19.7 m, from Nose

Offset of CB : 18.8 m, from Nose

Offset of CG : 23.6 m, from Nose

b. Tether Parameters

Maximum Tether Length : 1500 m

Diameter : 18 + 0.5 mm

Tether Bending Diameter (Minimum) : 0.6 m

Tether Weight : 0.4 kg/m

c. Capstan design Parameters

Maximum Tether Tension : 50000 N

Maximum Full Load Speed : 75 m/min (at 34000 N)

Brake Holding Capacity : 100000 N

d. Stow drum & Spooler Parameters

Storage capacity : 1500 m length of tether

Maximum Tether Tension : 15000 N

e. Close Haul Winch Parameters

Maximum Cable Length Handled : 60 m

Maximum Operational Speed : 30 m/min (at 15000 N)

Brake Holding Capacity : 30000 N

f. Load values

Case – I: Balloon is in moored condition, Wind Direction Parallel

to balloon longitudinal Axis and blowing at a speed of 70 knots

(36 m/s), both the close haul lines are secured:

Drag and lift forces are

Wind speed (m/sec)

Balloon Angle of attack Drag Force Lift Force

36 00 6071 N -74 N

36 +60 7592 N 16839 N

36 -60 6322 N -16706 N




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Case – II: Balloon is in moored condition; Wind Direction

Parallel to balloon longitudinal Axis and blowing at a speed of 70

knots (36 m/s), one of the close haul lines snaps off.:

Case – III: Balloon is in moored condition; Wind Direction


knots (36 m/s), both the close haul lines snaps off.:

Case – IV: Balloon is in moored condition; Wind Direction


knots (36 m/s), nose lines snaps off.:

Case – V: Balloon is in moored condition; Wind Direction

perpendicular to balloon longitudinal Axis and blowing at the

speed of 20 knots (10.29 m/s), Bearing fails and not rotating:

Case – VI: Balloon is in flying condition;

Tether tension at 50 knots (25.72 m/s) wind speed: 50000 N

Case – VII: Winch and mooring system is in transportation mode

and system is in collapsed condition;

Vertical Acceleration : 2g

Horizontal Acceleration : 2g, with 1g vertical acceleration

Lateral Acceleration : 1.2g, with 1g vertical acceleration

All accelerations occur exclusive to each other




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4.0 Subsystem Description:

4.1 Fabricated structure:

The fabricated structure consists of following subsystems:

I) Mooring tower

II) Boom

III) Close haul swing frame

IV) Frame skin (shelter)

V) Pedestal

VI) Trailer with outriggers

4.1.1 Mooring Tower:

Mooring Tower is required to hold and anchor the balloon at

nose with the help of cradle and latch assembly. It is made of marine

grade anti-corrosive steel. The structural design is well supported by

FEM analysis. It can be folded in transportable mode.

Fig. 10: Mooring Tower (dimensions are for reference only)




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Fig. 11: boom

4.1.2 Boom:

Boom is the main platform upon which mooring tower, inflatable

trestle airbags, close haul swing frame, flying sheave, capstan, stow

drum and spooler, hydraulic power pack and other sub-systems with

winch enclosure are mounted. It is a made of marine grade anti-

corrosive steel. The design of the boom is well supported by FEM

analysis.

4.1.3 Close haul Swing frames:

Close haul swing frames one each at the port and starboard side

of the boom is to be provided to mount the close haul winches. The

frames are foldable so that it can be folded during transportation. The

design of the boom is well supported by FEM analysis.

Fig.12: Close Haul Swing Frame (dimensions are for reference only)




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Fig. 13: integrated mooring tower, boom and close haul swing frames

SPECIFICATION SHEET FOR ASTAT MOORING STRUCTURE

1. Application To mount winch system and its all accessories 2. Quantity 01 No. 3. Configuration Compact and light weight design 4. Design

Requirements � It must have one point support at slewing bearing � To mount winch system and its all accessories, one

main frame should be there (usually known as boom).

� To mount cradle, it should have mooring tower. � To mount two close haul winches, it must have two

close haul swing frames � To vary the position of close haul winches, close

haul swing frame must have locking arrangement at a particular location

� The system is transportable so mooring tower and close haul swing frames must be foldable

� All accessories to be mounted on boom in such a way that the CG of system is very close to axis of slewing bearing

5. Design Parameters Forces transferred from balloon to mooring structure 6. Design

methodology Theoretical analysis supported by FEM analysis for all four load cases (ref Para no. 3.2 (xxxvii)(f))

7. Overall Dimension For transportable condition: Length (l): 12 m, Width (w): 2.5 m, Height (h): 3.7 m

8. Material Marine grade anti-corrosive steel or equivalent 9. Weight Minimum




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4.1.4 Frame skin (shelter):

To protect the vital tether in stored condition from environmental

condition Winch enclosure, which contain hydraulic power pack,

Capstan, stow drum etc. is covered with shelter. The winch enclosure

is air-conditioned.

4.1.5 Pedestal:

Pedestal forms an interface between trailer and rotating mooring

station. It is mounted on the trailer using bolts. The pedestal cavity

houses the slewing bearing and the system power slip ring and FORJ

assembly, which is required for two way power and data transmission.

4.1.6 Trailer:

The entire winch and mooring system is mounted on a trailer to

ease the transportation. The trailer used is of a semi low-bed

configuration with four extending outriggers, which can be attached to a

tow vehicle for relocation. The trailer should be able to travel in the

desert condition. The extended outriggers offer added stability to the

system during operation. Electrically/hydraulically operated side riggers

will be provided to secure the trailer during deployment of Aerostat.

Four (4) numbers of hooks should be provided to lift the whole system

(trailer plus winch and mooring system) through crane.

Fig. 14: Pedestal




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Fig 15: Trailer

4.2 Docking and tether routing Units:

The docking unit is normally used for docking the balloon to the winch

and mooring system however the tether routing units guide the tether from the

balloon to the stow drum. The docking unit consists of following

i) Cradle assembly

ii) Flying sheave

iii) Tether Guide rollers assembly

iv) Tether Guide sheave assembly

v) High tension sensor assembly

vi) Low tension sensor assembly

4.2.1 Cradle assembly

The Cradle is mounted on the top of the Mooring tower and serves as

a docking point for the balloon Nose during launching and recovery of the

Aerostat. It is in the form of conical shape. Cradle is fitted with latching




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assembly and capable of tilting +125 degree up and -45 degree down in the

vertical plane by means of a hydraulic actuator. The actuation of the hydraulic

actuator is controlled by operator sitting in the control cabin. The nose probe

is design and fabricated to suit the latch assembly for proper and easier

docking and undocking.

Fig 16: Cradle assembly

4.2.2 Flying sheave

Flying sheave is used to guide the tether coming from Aerostat to

capstan and the main winch through the set of pulleys. It consists of large

pulley that is pivoted so as to allow rotation about the two axes. It is fitted with

the counterweight. The design of flying sheave allows it to orient itself based

on Aerostat location and maintain the minimum bending diameter of the

tether.

Fig 17: Flying Sheave




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4.2.3 Tether guide rollers assembly

These units help the tether to route from the flying sheave to the

capstan. These units are used where the space is not available to

mount the sheave.

Fig 18: Tether guide roller assembly

4.2.4 Tether guide sheave assembly

Tether guide sheave assembly helps to guide tether from the

flying sheave to the capstan.

Fig 19: Tether guide sheave assembly

4.2.5 High tension sensor assembly

Two tension-sensing units are used to measure the tension of

the tether. The first unit, which is called the high tension sensor

assembly is fitted between the Flying Sheave and the Capstan and




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used to measure the tether tension which is on the higher tension side

of the capstan. The tension on this side ranges from 0-90000 N.

Fig 20: High tension sensor assembly

4.2.6 Low tension sensor assembly

The second unit which is called the high tension sensor assembly is

fitted between the Capstan and the spooler pulley and used to measure the

tether tension coming after the reduction of tension from the capstan. The

maximum tension experienced in this region is 6500 N.

Fig 21: Low tension sensor assembly

4.3 Winch Assemblies

Launching, recovery, in-hauling, out-hauling operation of the balloon

are carried out using the various winches. The Capstan, Stow Drum and the

Spooler are used for tether handling. Launching & recovery operation is

achieved by two Close Haul winches and the Nose Line Winch. All controls to




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these winches are available to the operator at the Operator Control Desk.

Winch assembly consists of following:

i) Capstan,

ii) Stow drum with spooler,

iii) Close haul & nose line winches

4.3.1 Capstan

The function of the Capstan is to reduce the tether tension prior

to stowage on the Stow Drum, therefore preventing the tether from

getting crushed when stored in multiple layers. The Capstan consists of

two grooved drums around which the tether is wrapped prior to feeding the

stow drum. These drums are mechanically synchronized and are driven by

a single hydraulic motor via a reduction gearbox and clutch. It is primarily

driven by the hydraulic motor, the speed of which is controlled from the

Operator Control Desk. A manual drive should also be provided for

redundancy. For this shifting provision should also be given. The capstan

should be provided with integral fail-safe parking brake unit that prevents

the tether from unwinding under operational loads. The brakes are sized

for braking torque equivalent to 9000 kgf tether tension at capstan.

Fig 22: Capstan




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SPECIFICATION SHEET FOR ASTAT CAPSTAN

1. Application : Tether tension relieving prior to storage on stow drum

2. Quantity : 1 no.

3. Configuration :

Dual Cantilevered drums – Vertical stacking

4. Tether Details

:

Diameter : 18+0.5 mm

Total Length : 1500 m

Tether weight :0.4 kg/m (estimated)

5. Drum

Dimensions :

Grooved Hollow Drum (Linear Grooves)

Mean Diameter at drum groove : 620 mm

No. of grooves on drum : 5

No. of layers : 1

Groove Outer Diameter : 640 – 650 mm

Drums to have identical construction

Drums when assembled to have half pitch groove offset

Vertical offset between drums to be minimized

6. Drum Shafts : Hollow shafts ( 2 Nos.)

7. Design

Parameters:

Maximum Tether Speed : 75 m/min

Operational Tether Tension : 34000 N

Brake Holding Tether Tension : 100000 N

8. Input Power From Hydraulic motor

9. Gearbox :

1 No. integrated gearbox

*Gearbox Efficiency > 85 % to be ensured

*Manual operation: Should function with hydraulic 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




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10. Features : Peripheral rollers to be provided around drums to ensure

tether does not leave groove when slack Protective cover to

be provided over drums, absence of which should not hinder

Capstan operation

Protective cover to have tether inlet and exit cut-outs

Provision for lifting lugs to lift entire Capstan unit vertically

System weight optimization to be enforced during design

All manual interfaces to be accessible from motor side

All sharp corners in path of tether to be rounded off

11. Weight: Minimum

Note : This specification sheet are for reference o nly.

4.3.2 Stow drum with spooler

Stow Drum and Spooler are used for tether stowage after

tension relieving at Capstan. It should have capacity to store 1500m

length of tether. The stow drum and spooler are driven using a single

hydraulic motor. It should be fitted with an integral fail-safe brake to

prevent tether unwinding when not in operation. Provision should also

be made on the stow drum for manual operation using a hand lever.

Due to increase in diameter when tether is stored in multiple layers on

the stow drum, the linear velocity of tether at stow drum and at capstan

tend to vary, leading to fluctuation in tether tension. So a

synchronization of speed between the capstan and stow drum is

required to be taken care during designing of the system. This

synchronization should be done electronically as well as the

mechanically.

The Spooler is used for level winding of tether on the Stow

Drum. This is achieved by double helix diamond screw and pawl

arrangements. The diamond screw is driven by stow drum hydraulic

motor via the gearbox. The Stow Drum is mechanically synchronized

with the Spooler for uniform tether winding on the drum. For every turn




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of the drum the spooler pulley moves by 1(one) tether pitch distance

linearly. The Stow Drum can be disengaged from the spooler by

removing the coupling between them to allow manual correction to

spooler carriage location during initial tether winding on the drum or

intermittently.

Fig 23: Stow drum & spooler

SPECIFICATION SHEET FOR ASTAT STOW DRUM & SPOOLER

1. Application : Storage of tether after tension relieving at capstan

2. Quantity : 1 no. 3. Configuration : Perpendicular tether feed (parallel to drum axis)

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




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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


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.




34

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.




35

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.




36




37

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




38

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




39

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




40

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.




41

(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




42

� 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:




43

I) Motor-1 (ON/OFF)

II) Motor-2 (ON/OFF)

III) Hydraulic Motor 1 ON F/B

IV) Hydraulic Motor 2 ON F/B

V) Nose Probe lock (Engage/ Disengage)

VI) Nose probe (Engage/ Disengage)

VII) Pneumatics (ON/OFF)

VIII) Pneumatic Pressure Sensor 1

IX) Pneumatic Pressure Sensor 2

X) Trestle (Inflate/ Deflate)

XI) Hooter (Acknowledge)

XII) Footswitch (Trigger)

XIII) Capstan Manual( Engage/ Disengage)

XIV) Strowdrum manual (Engage/Disengage)

XV) Stowing Drum( Standby/ Primary / Emergency mode)

XVI) Capstan (Standby/ Primary / Emergency mode)

XVII) Left Haul Winch (Standby/ Primary / Emergency mode)

XVIII) Right Haul Winch (Standby/ Primary / Emergency mode)

XIX) Cradle Actuator (Standby/ Primary / Emergency mode)

XX) Tower Elevate (Standby/ Primary / Emergency mode)

XXI) Nose Line Winch (Standby/ Primary / Emergency mode)

XXII) Pedestal (Standby/ Primary / Emergency mode)

XXIII) Cradle Free Slide (ON/OFF)

XXIV) Spooler Manual (Engaged/ Disengaged)

XXV) Chillier Unit (OFF)

XXVI) Oil level Critical

XXVII) Pressure line filter Clogged

XXVIII) Return line filter Clogged

XXIX) Suction line offline

XXX) Suction line 1

XXXI) Suction line 2




44

XXXII) Main Supply is OFF (Display)

XXXIII) 7th turn proxy tripped

XXXIV) Spooler manual (Engaged/ Disengaged)

XXXV) Hydraulic Power Pack Motor 1 ON

XXXVI) Hydraulic Power Pack Motor 2 ON

XXXVII) Pneumatic ON

XXXVIII) HPP (Loading/Unloading)

XXXIX) Cradle Actuator (free Slide)

XL) Capstan Motor ( Displacement Pilot signal- Solenoid 1)

XLI) Pedestal Clutch Operation

XLII) Pneumatic Solenoid 1

XLIII) Pneumatic Solenoid 2

XLIV) Stowing drum Lamp ( Primary / Emergency mode)

XLV) Capstan Drum Lamp ( Primary / Emergency mode)

XLVI) Left Haul Winch Lamp (Primary / Emergency mode)

XLVII) Right Haul Winch Lamp (Primary / Emergency mode)

XLVIII) Cradle Actuator Lamp (Primary / Emergency mode)

XLIX) Tower Elevated Lamp (Primary / Emergency mode)

L) Pedestal Lamp (Primary / Emergency mode)

LI) Nose Probe Docked Lamp

LII) HPP Motor-1 Lamp ON

LIII) HPP Motor-2 Lamp ON

LIV) Nose Probe Lock Engaged

LV) Pneumatics lamp ON

LVI) Trestle(Airbag) Inflate Lamp

The PLC controls in Analog mode the following elements of WM

system:

i. Pneumatic Pressure Sensor

ii. Temperature Sensor




45

iii. Joystick Travel (X/Y Axis)

iv. Tensometer-1 feedback (HTS)

v. Tensometer-2 feedback (LTS)

vi. Stowing drum Proportional Valve

vii. Capstan Proportional Valve

viii. Close Haul Winch Right Proportional Valve

ix. Close Haul Winch Left Proportional Valve

x. Nose Line Winch Proportional Valve

The two counter modules of 2 Channel and 4 Channel controls the

Capstan and Stow drum.

The Block diagrams of the various channel is shown in the

succeeding pages. These block diagrams are for refe rence only. The

actual configuration and the system will be finaliz ed during design and

review of the system.




46

i. Block Diagram of PLC based WM System:

The details of the Digital Signals, Analog signals and Counter Modules are mentioned below:

Central Power Supply

Operating System (HMI Software)

Central Processing unit with Ethernet Port

Digital Input Port

Digital Output Port

Analog Input Port

Analog Output Port

Counter Module 2 CH

Counter Module 4 CH

Joystick and Keyboard Inputs

Analog O/p Signals

Ack. and Feedback Signal

Digital Signals


Capstan Stow drum

Feedback Sig

Feedback Sig




47

Joystick and Toggle Switch Input for the Operation of Actuators

Cradle

Pedestal

Close Haul winch (R)

Close Haul winch (L)

Nose Line Winch

Tower Elevator

Capstan Stowdrum

Hydraulic Actuators of Winching Assembly


Display on Screen Via (HMI Software) 230 VAC

Turn Count Signal of Capstan

Turn Count Signal of Stowdrum


Digital Signal

Central Power Supply


Analog Input Port

Analog Output Port

Digital Input Port

Digital Output Port

Counter Module 2 CH

04 Redundant Channels for further Expansion

Counter Module 4 CH

0-10 V 0-10 V 0-10 V 0-10 V 0-10 V 0-10 V

0-10 V 0-10 V

0-10 V (x-axis) 0-10 V (y-axis)

24 V

Encoder Encoder Encoder Encoder

Encoder

Limit Switch

Limit Switch

Praportional Valve to control oil flow




48

iii) Digital Input/ Output elements of WM system

iv) Analog Input/ Output elements of WM system

Pedestal (S/ P/ E mode)

Tower Elevate (S/ P / E mode)

Nose Probe lock (Eng/ Diseng)

Nose Line Winch (S/ P / E mode)

Capstan Manual( Eng/ Diseng) Capstan (S/ P/ E) Stowdrum manual (Eng/Diseng) Stowing Drum( S/ P/ E mode)

Left Haul Winch (S/ P/ E mode) Right Haul Winch (S/ P/ E mode) Spooler Manual (Eng/ Diseng) Suction line offline/1/2 Pressure/ Return line filter Clogged Capstn Motor ( Disp. Pilot sig- Solen 1) Spooler manual (Eng/ Disen) 7th turn proxy tripped

Cradle Actuator (S/ P/ E mode) Cradle Free Slide (ON/OFF) Cradle Actuator (free Slide)

Pneumatics (ON/OFF) Pneumatic Pressure Sensor ½ Pneumatic Solenoid 1/2

Trestle (Inflate/ Deflate) Footswitch (Trigger) Chiller Unit (OFF) Pedestal Clutch Operation

Hooter (Acknowledge) Main Supply is OFF (Display) Lamp (P/ E mode): Trestale Inflate /Pneumatics /HPP Motor 1-2 / Nose Probe Docked /Stowing drum /Capstan Drum /Left Haul Winch /Right Haul Winch /Cradle Actuator /Pedestal/ Tower Elevated

Motor-1/2 (ON/OFF); HYD Motor 1/2 (ON F/B) Oil level Critical HYD Power Pack Motor 1/2 ON HPP (Loading/Unloading)

Digital Input Port

Digital Output Port

Central Processing unit with Ethernet Port (Slot 1)

Feedback/Acknowledgement




49

v) Counter Module elements of WM system

(b) Motor starter Panel:

Stowing drum Proportional Valve Capstan Proportional Valve Close Haul Winch Rht Prop. Valve Close Haul Winch Lft Prop. Valve Nose Line Winch Prop. Valve

Joystick Travel (X/Y Axis)

Tensometer-1 feedback (HTS); Tensometer-2 feedback (LTS)

Temperature Sensor

Pneumatic Pressure Sensor

Central Processing unit with Ethernet Port (Slot 1)

Analog Input Port

Analog Output Port

Feedback/ Acknowledgement


Feedback/ Acknowledgement

Counter Module 2 CH

Counter Module 4 CH

Capstan Stow drum




50

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


(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




51

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




52

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


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




53

(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

minimum features are:

250 GB Hard disc(or higher), 2 GB DDR2 RAM (or higher), 13.3”

LCD, Intel core 2 duo with corresponding motherboard, standard port

and interfaces like RJ 11, RJ 45, Serial, 4 USB, port replicator

interface, VGA out, Audio in out, Intel 3945 a/b/g, 10/100/1000 Gigabit

NIC, Blue tooth, DVD writer, standard keyboard with touch pad, pre

installed Windows 7 professional, battery life not less than 6 hours etc.

The portable data storage and analysis device should be of

reputed make. The some of the minimum features are:

500 GB Hard disc(or higher), 3 GB DDR3 RAM (or higher), 12.1”

TFT, Intel core i7 processor with corresponding motherboard, standard

port and interfaces like RJ 11, RJ 45, Serial, 4 USB, port replicator

interface, VGA out, Audio in out, Intel 3945 a/b/g, 10/100/1000 Gigabit

NIC, Blue tooth, DVD writer, standard keyboard with touch pad, pre

installed Windows 7 professional, Web camera, battery life not less

than 4 hours etc.

(g) List of electronic control system deliverables:

(i) Master controller

(ii) System Software with their licenses

(iii) Console with HMI, CPU

(iv) Feedback Sensors




54

(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 –� 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




55

4.6 Miscellaneous subsystem

4.6.1 Pedestal Drive and Slewing Bearing

The entire mooring station is mounted on the pedestal using a slewing

bearing. The slewing bearing allows the station to be rotated continuously

about the vertical axis. The powered drive unit coupled to the slewing bearing

allows the complete winch and mooring system to be oriented as required

using a hydraulic motor. The operational controls for this are available at the

operator control desk. It can be disengaged from the operator control desk to

allow wind waning.

The specification of this subsystem is given below:

Specification Sheet - Aerostat Pedestal Drive

1. Application: Flange mounted Pedestal Drive with

integral clutch for Mobile application

2. Dimensional Data:

Mounting PCD

Body diameter

Total height

< 500 mm

< 350 mm

< 300 mm (from mounting flange to

motor end face)

3 Input Interface: Hydraulic Motor

4. Output Torque: Dynamic: 1500 Nm

5. Output Speed: 5 rpm

6. Output Pinion Details: Module = 5

Number of teeth = 73

7. Output Interface:

Length of pinion shaft such that length

from mounting face to pinion center =

48 mm

8. Clutch Details: Hydraulically engaged spring released

clutch. Preferably non friction based

positive engagement

9.

Sealing: Fully sealed against ingress of dust /

water




56

10. Weight: Reduced component weight preferred

11. Life: 10 years (assuming operated (@ 2hrs

per day)

> 7200 hours (1.8 X 105 (No. of cycles

@ 25 half cycles


Specification Sheet - Aerostat Slewing Bearing

1. Application: Slewing Bearing for Mobile

application (Wind-vaning Station)

2. Bearing Type: Slewing bearing With Internal Gear

3. Make: Rothe Erde, Germany or Equivalent

4.

Dimensional Data: Maximum External

Diameter:

Maximum Height :

2000 mm

300 mm

5.

Accuracy

Axial Run out on the mounting faces:

Radial run out on locating spigots:

Run out on gear PCD:

< 0.2mm

< 0.2 mm

< 0.12 mm

6. Starting Torque: < 1000 Nm

7.

Bearing Loads:

During Transportation:

Operational load:

60 ton

30 ton

8.

Gear:

Maximum Operational Torque :

Operating Speed :

6 kNm

1 rpm

9. Sealing: Fully sealed against ingress of dust /

water

10. Weight: Reduced component weight

preferred




57

11.

Bearing Life: 10 years (assuming operated(@

2hrs per day)

> 7200 hours (1.8 X 105 (No. of

cycles @ 25 half cycles per hr))

Suitable azimuth rotating mechanism or equivalent may be used which meets

system requirement.


4.6.2 Air Conditioning System

Air conditioning system is used to maintain the temperature and

humidity of the operator cabin as well as the winch enclosure. The air

conditioner should be suitably chosen so that the temperature inside the

operator cabin and the winch enclosure is comfortable even at the extreme

operating condition. Air conditioner should have MIL grade type.

4.6.3 Pneumatic System and Air bags

The Pneumatic System is solely for the purpose of inflating and

maintaining the pressure in the Air Bags during operating conditions and to

deflate Air Bags during transportation condition. Pneumatic system consists

of compressor/ air cylinder, vacuum pump, air bags, pressure control valve

and other accessories. Compressor/air cylinder and vacuum pump is used to

inflate and deflate the air bags respectively. To control the pressure of air

during the inflation or deflation of air bags, pressure control valves are used

along with other accessories to ensure the proper distribution of air.

The function of the airbags is to support balloon in docked condition. It

is suitably located on the winch and mooring system. It has two frames which

are welded to the main structural frame of the station. Each frame carries an

inflatable Air bag, which provides cushioned support to Aerostat to keep it in

horizontal position.

4.6.4 Lightning Protection: The tether is having lightning braids to cater 100

k Amps lightning. Adequate path should be available to earth the lightening.




58

5.0 Scope of Work

It includes development, fabrication, supply, integration of structural,

hydraulic & control system, installation, commissioning of the system at

ADRDE and conduct test trials as per ATP. This system requires a preliminary

& critical design analysis, Material Selection, preparation of drawings,

Fabrication & testing techniques. Finite Element Analysis of various structural

members would be necessary to arrive at a rational mechanical design of the

system. The scope of work mainly includes following:

a) Design of whole system based on specification including FEM

analysis of the system.

b) Preparation of Configuration Document, Preliminary Design Report

(PDR), Critical Design Report (CDR) etc.

c) Review of the design by experts to be nominated by ADRDE.

d) Preparation of manufacturing drawings of all the systems and

components including assembly drawing in AUTOCAD and 3D

modelling duly approved by ADRDE. (The firm should have in

house CAD facilities and they are at least 5 years experience in

fabrication and FEM analysis of structures and components).

e) Review of acceptance Test Procedure (ATP) based on draft ATP

provided by ADRDE and then preparation of final ATP.

f) Preparation of QAP and WPS (Welding Procedure Specification)

Document.

g) Fabrication of the complete system.

h) Testing of sub-assemblies of the system as per ATP at firm’s

premises.

i) Integration, installation and commissioning of whole system at

ADRDE, Agra or place provided by ADRDE, Agra.

j) Fabrication of test jigs and fixtures required in manufacturing and

testing.

k) Acceptance Testing as per final ATP.

l) Preparation of Test Report (including stage inspection report).




59

6.0 Inspections and Acceptance Procedure:

During complete execution of the job, inspection will be carried out by

the Director ADRDE, Agra or his authorized representative. The inspection

will be carried out in stages for raw materials, machined components,

assembled components and bought out components. The contractor shall get

the drawings approved for every component including structure, hydraulic

circuit, various sensors and bought out components. All the material to be

procured by the contractor shall be inspected by the inspecting authority i.e.

Director ADRDE or his authorized representative. Stage inspection shall be

carried out for subassemblies during fabrication. Contractor shall keep

informed the inspecting authority on the progress of work and shall notify the

inspecting authority well in advance. Inspection report format for each

component has to be filled in separately for critical dimensions on each

component using calibrated instruments only. All inspection, measuring and

test equipment should have valid calibration as per ISO 9001 requirements.

The system should be inspected and accepted as per final ATP which will be

prepared after the review however the draft ATP is given in the Annexure –I .

7.0 Painting:

i) Cleaning: The surface to be painted shall be prepared to ensure

complete removal of grease, rust scale corrosion, slag etc.

Mechanical cleaning involving Scraping, wire brushing, rubbing

with abrasion paper may be used.

ii) Primer Coat: Primer coat shall consist of red oxide zinc chrome

confirming to IS: 2074. Two coats of this shall be applied as per

the procedure laid down in IS 1477 – Part II. (painting process to

be approved by ADRDE)

iii) Finish Coat: Two coat of OG colour paint.

iv) Adequate internal protection should be provided to the structure

components used as hollow sections.




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8.0 Integration, Installation and commissioning:

The integration, installation of the whole winch and mooring system will

be carried out by the contractor initially at firm’s premises and then at ADRDE,

Agra or the place provided by ADRDE Agra. After the installation the system

will be commissioned by the firm at ADRDE, Agra or the place provided by

ADRDE Agra.

9.0 Materials for Fabrication/Integration/installat ion:

i) All the materials, tools, accessories, Welding set, crane required

for integration and testing is to be arranged by the contractor at

the work site (at firm premises or at ADRDE or place provided

by ADRDE) at his own cost.

ii) All the materials required for fabrication will be procured by the

contractor along with their relevant test certificates. Material

procured by the contractor for machining and fabrication work

should confirm to relevant IS specification. Material, which is not

confirming to the specification, will be rejected and will be

replaced by the contractor at their (contractor) cost. The

contractor shall furnish test certificates for all the material

purchased by him confirming to relevant standards before

commencement of work. Material shall be tested for its chemical

composition, mechanical properties, ultrasonic test etc to detect

any flaws before fabrication. The materials shall be stamped by

the inspection agency before fabrication.

iii) Firm should submit the QAP document, which will describe how

raw material will fabricate into component.




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10.0 Quality control: As quality is integral part of the service process, so to enable the

effective control of each service process the contractor should use calibrated

instruments during manufacture of all the components. If such calibrated

instruments are not available, the contractor should make necessary

arrangements and provide calibrated instruments to the inspector as and

when inspection is carried out. The contractor should strictly adhere to the

tolerances specified in the approved drawings. Contractor should submit

quality test plan along with technical bid.

10.1 Quality control for wel ding:

i) Welding sequence shall be such that the distortions and

residual stresses are minimized. All welds shall be

deposited in proper sequence so as to balance the

applied heat as far as possible.

ii) All welding shall be carried out by qualified and approved

welders. Quality of welds carried out by the welders shall

be tested in accordance with IS:7318 before the welder is

permitted to do the welding.

iii) In case of fillet welds, test coupon shall be made and

subjected to dye penetration test. The welding

parameters of the accepted weld coupon be established

and ensured in case of fillet welds.

iv) Weld metal shall be solid except for the fine scattered

porosity and small inclusions of oxides or slag may be

overlooked.

v) There shall be complete fusion and penetration between

the weldment and the parent material during the

successive runs.

vi) Firm should submit the WPS (Welding Procedure

Specification) document.




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11.0 Perfection of Work:

i) All components and accessories shall be suitable for open field

operating conditions including dust, sand, rain, salinity etc. For this,

all components shall have anticorrosion treatment & should be dust

proof. All mating components shall have proper lubricating

arrangements.

ii) The workmanship shall be of the highest in order. All components

should be free from burrs, sharp edges and finished smooth.

iii) All components and accessories having same part numbers shall

be directly interchangeable with respect to installation and

performance. The list of all spares should be supplied

iv) The components that are used in fabrication of this system should

be of reputed firm/company. The overall workmanship shall be of

best quality to the satisfaction of inspection agency. All

components/accessories should be of best trade quality and as far

as possible should conform to IS specification.

v) In the hydraulic drives, all the pipes should be bent neatly to the

appropriate angle and be properly clamped and secured. Sharp

bends should be avoided. No leakage what so ever in pipe joints

and connections are allowed.

vi) The electric motor along with the hydraulic pump, hydraulic motor

and all other accessories shall be properly placed and mounted.

vii) All the control valves shall be properly mounted on a panel in such

a way that all the hydraulic components/fittings should be easily

approachable and if needed be easily removable and re-fittable

during repair/maintenance.

viii) Hydraulic power pack shall be compact in design.

ix) Fabricated components should be free from burs and sharp edges.

x) The fabrication and welding of system shall be of highest quality.




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xi) All the components shall be manufactured as per the tolerances

mentioned on the approved drawings. Unless otherwise specified,

the tolerance for fabrication shall be as per IS: 2102 – 1993.

xii) All supplied electronics subsystems should be of Industrial/MIL

grade. All electrical subsystems should meet environmental

condition as per JSS 55555.

xiii) All sub-vendor (if any) should be approved by DIRECTOR, ADRDE.

12.0 Safety requirements:

Safety has to be of prime importance to avoid any accident and injuries

to the personnel working on the system. The following safety measures

should be kept in mind during integration:

i) All high pressure components/lines shall be properly covered to

avoid damage due to falling of some objects or tools and prevent

people to step on such components/lines during working.

ii) Proper colour code shall be followed for marking of

components/lines as per standard practice.

iii) All hydraulic pipe lines shall be properly clamped as per standard

practice to avoid loose connection and thereby leakage due to

vibration during running of pump and motor.

iv) Indian standard IS: 10481 – Guide lines for application and

installation of oil hydraulic system shall be followed for installation of

hydraulic system.

v) Items that will be used for the fabrication of the above system

should be of flame proof quality.




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13.0 Tools for maintenance:

i) Tools like Allen Key set inch and mm series, double ended spanner

set, screw driver pipe wrench, adjustable wrench and any tools

required for maintenance of hydraulic system or any component to

be supplied by the contractor with the system.

ii) Special maintenance tool required for specific hydraulic

components as well as other components shall be supplied by the

contractor.

14.0 Jigs and Fixtures

All critical welding shall be carried out using welding fixtures. The

welding fixtures shall be designed and fabricated by the firm. These shall be

approved from the inspector. All the welding fixtures shall be robust for

repetitive use. The welding fixtures shall not develop undesirable clamping

stresses in the components being fabricated. The welding fixtures shall

facilitate easy and proper welding of components from all sides.

15.0 Deliverables:

a) 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.

b) 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.

c) QAP and WPS Document in both hard as well as soft (in solid model)

form. Document should be given in doc format.

d) One set of fabricated Winch and Mooring System along with Trailer

and spares. List of spares is attached as Annexure -II.

e) Schedule of spare parts with proper part nos. and source of supply and

portable rate of consumption.




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f) List of all brought out items with their test certificates.

g) System description, Operational, maintenance and repair/trouble

shooting manuals.

h) Inspection and test reports of all components as well as the assembly.

i) Compliance report of the Acceptance test of the winch and mooring

system.

j) Part list, part specification with literatures of all components. The

catalogue and data sheet of all brought out item.

k) Drawings of hydraulic circuit and plumbing and bill of materials.

l) 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.

m) Recommended spares for two years maintenance shall be supplied.

n) Spare kit as recommended by manufacturer for all hydraulic

components/ control valves and accessories used in the system shall

be supplied.

o) Hydraulic hoses, tubes, end fittings connectors etc. required for two

years of maintenance of the system are to be supplied.

p) Access ladders

q) Electronics deliverable as per point no. 4.5.1.(g)

r) Warranty certificate of the complete winch and mooring system.

16.0 Time Schedule:

The complete system is expected within 18 months from placement of

SO. Total execution time shall be indicated with detailed activities like

preparation of manufacturing drawings, procurement of materials, fabrication

integration testing delivery etc shall be indicated in pert chart form at the time

of tendering. The same shall be reviewed and up dated fortnightly till the

delivery of the whole system. Firm should submit total plan and PERT chart

along with technical bid.




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17.0 Guarantee/Warranty:

The system shall be covered by a warranty for a period of two (02)

years against malfunctioning, material and manufacturing defects.

18.0 Product Support:

The contractor shall quote separately for comprehensive Annual

Maintenance Contract (AMC) for a period of three (03) years after the

completion of guarantee/warranty period, which shall include regular

maintenance and fault repair including spares and consumable to be

undertaken beyond the free warranty/guarantee period as well.

19.0 Presentation:

The firm should give presentation before a committee, which include

understanding of the complete system and how they complete the total task in

given time frame with the PERT chart .

20.0 Compliance sheet:

The contractor has to submit the completed compliance sheet

(enclosed as Annexure –III) and questionnaire (enclosed as Annexure –IV) to

ADRDE during submitting the tender Form.




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1.0 SCOPE

This Acceptance test plan covers the test, inspection and acceptance

procedure of winch & mooring system for Medium size aerostat.

2.0 GENERAL

2.1 All the raw material should conform to relevant specifications as

mentioned in the drawings.

2.2 Manufacturer shall submit test reports of all raw material, only

from govt. recognised labs. Along with a certificate that all

material conform to relevant specification.

2.3 Rep ADRDE at his discretion, can draw samples from the

material and carryout test at ADRDE or at the lab considered

appropriate.

2.4 Vendor will undertake 100% inspection of all components/parts

and Inspection reports will be submitted to ADRDE.

2.5 Variation if any, observed in critical dimension/parameters, the

part/ component would be rejected.

2.6 Manufacture has to follow the process as, described in the

drawing only. Variation from specified process should have prior

approval of designer/ADRDE. Product will be rejected if process

has not been followed as per specification/ as mentioned in the

drawings.

2.7 All the test will be carried out in the ADRDE/Vendor’s Premises

or any other place with the approval from ADRDE, Agra.

2.8 All the checks/Tests are to be performed in presence of

ADRDE, Agra representative and a Vendor

Representative.

2.9 Vendor will provide test certificates of the all the brought out

items.

Acceptance Test Plan (Annexure - I)




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3.0 TEST CLASSIFICATION

In this section we mention all the tests to be performed prior to

acceptance of the systems.

3.1 Preliminary Checks

i) Objectives:

a) To check whether the dimensions of all components are within

specified tolerances or not.

b) To check whether material of requisite strength and chemical

composition is used or not.

c) To check whether finish and workmanship of the components are of

good quality or not.

ii) Preliminary test consist of following type of t ests

a) Dimensional checks:

All the machined components should be checked for their

dimensional accuracy within the tolerances specified in the drawings.

These checks should be performed using suitable measuring

instruments.

b) Material checks:

All the materials used in the fabrication of various winch

components should be test for their Chemical composition and

Mechanical properties. The tested properties should have values in

accordance with those specified in the relevant standards.

c) Welding test:

Welding test is to be done during fabrication and after

fabrication. Vender will submit all the test reports.





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(d) Finish and workmanship test:

All the machined components should be checked for Lay,

Waviness, Surface flaws, Burrs by means of a Surface micrometer. All

plated components should be tested for the plating thickness, which

should be in accordance with thickness specified in the relevant IS.

This test is essential to ensure that the peeling of plating does not

occur.

e) Lubrication Check:

The lubrication of the moving parts of the system should be

checked by imparting motion to them under No load, Full load and

Overload conditions. The motion in each of these cases should not be

accompanied by any abnormal noise due to friction or misalignment.

f) Hydraulic checks:

All brought items are checked for their test certificates. The

fabricated components are checked for their intended use and

functionality in standard hydraulic test bench or govt. approved

laboratories in standard testing conditions.

3.2 Functional Test

The functional test can be classified into two phases

3.2.1 Phase 1 (Winch assembly)

All the tests performed on winch is to be done using suitable

Test Winch which is to be fabricated by the vendor at their premises.

The test winch should be duly approved by ADRDE, Agra. Following

are the list of tests to be conducted:





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(a) Capstan Brake load holding test:

Capstan is tested for its braking capacity i.e. 90000 N. A load of

specified value will be applied on the tether wrapped over the Capstan.

Brake should not slip and no abnormal vibration and heating should be

observed in any component. This load is gradually applied on the

tether using a suitable actuator. At maximum load i.e. 90000 N load

should be applied for at least 5 minutes.

(b) Stow drum test and spooler test:

The objective of the test is to check the performance of the stow

drum with speed varying from 0 – 75 m/min at a load of 6000 N.

Minimum 4 complete layer on stow drum should be checked for proper

winding and unwinding.

(c) Nose line/close haul Winch Test

These winches are tested to winding and unwinding of the rope

for specified load and speed (i.e. 1500 kg and 30 m/min).

3.2.2 Phase 2 (Integration trials)

It consists of testing of the system after integration of each subsystem

a) Synchronization test

The objective of the test is to test the synchronization between

the capstan & stow drum assembly during operational loads.

The winch is run at full load i.e. 34000 N and at specified speed

i.e. 75 m/min for 5 cycles each in winding and unwinding mode with a

pause of 5 min. and ensures smooth functioning of subsystems. (one

cycle consist of winding & unwinding of min 350 m length of tether)

b) Starting friction torque test

The objective of the test is to verify the starting frictional torque

(1200 Nm) of the Slewing bearing when complete is mounted over the

slewing bearing.





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c) Structural test

The objective of the test is to check the structural strength of the

integrated system by simulating operational load conditions. The load

will be applied on the winch and mooring system at the various points

using crane etc. Based on the various load cases, critical load case(s)

has (have) been identified and accordingly load has been applied to

check the structural strength.

d) Cradle & latch Test

The cradle of the system should be checked for tilting through

actuator as well as the locking/unlocking of the nose probe in the latch

assembly. The locking mechanism of the nose probe will be checked

for 15000 N.

e) Mooring Tower actuator test

The objective of this test is to check the actuation mechanism of

the Mooring tower actuator & it’s load holding capacity for any angle

from 0 – 110 0.

f) Flying sheave Test:

Flying sheave should rotate 360 degrees freely around the

horizontal axis. It should also be able to tilt on both side (port side and

starboard side) up to the stopper and return back to nutral position

when tilting load has been removed.

It should also be tested for 9000 kg load. This load test can be

combine with the structural test.

g) Operational check and Leak test of Air Bags

The Air Bags have been inflated to its maximum allowable

pressure using pneumatic power pack and checked for any leakage by

applying soap solution.





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h) Load test

This test is performed basically to check whether the structure can

meet the loading requirements as stated in the specifications.

i) Operational check of Air Bags

The Air Bags of the mooring system should be capable of supporting

the aerostat without any leakage in the Air Bags.

j) Static Acceptance Test

The static acceptance test is intended to check whether the structure is

capable of carrying the design loads without undue distortion and

without developing serious defects.

3.3 Environmental Test:

All components/parts/subsystem supplied by the vender should

environmentally tested as specified in the specification. A test

certificate in this regard is provided by the vendor.

3.4 Integration Test (With balloon, tether etc.):

A complete trial integrating tether and Medium size aerostat will be

flown tested up to height of 1000 m and carried out performance checks as

specified in the specification. The system should meet all operational

requirements.





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List of Spare Parts for winch & mooring system for medium size Aerostat: Sl. No. Item Qty Remark

1. Close haul/nose line winch assembly 1 no. 2. Stow drum and spooler assembly 1no. 3. Capstan assembly 1 no. 4. Cradle 1 no. 5. Pedestal 1 no. 6. Flying sheave 1 no. 7. Control console 1 no. 8. Tether guide assembly 1 no. 9. High tension sensor assembly 1 no.

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)

COMPLIANCE SHEET (ANNEXURE – III)




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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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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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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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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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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.

(a) Fork lifter – 3 Ton or more.

(b) Crane 10 Ton capacity or more.

(c) Elevated platforms.

(d) Hydraulic trolley for lifting materials.

3

Installation, Integration, testing, Operation & Inspection Facilities

Whether the firm has the following:

(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.


Documents

Specification Adrde 210212