Professional Documents
Culture Documents
No. of pages
EXECUTIVE SUMMARY
Contents:
Executive summary .
Nomenclature
..
10
..
10
13
1.2 Duration
15
1.0 Introduction
..
15
18
18
..
..
29
29
30
31
2.3 Specifications
35
..
39
42
2.6 Documentation .
42
2.7 Deliverables
44
..
49
49
...
52
73
49
..
75
75
75
4.1.1 Introduction
75
76
77
..
83
83
83
4.2.1 Introduction
83
86
..
89
90
90
90
91
..
94
94
4.4.1 Introduction
94
95
97
..
99
99
99
4.5.1 Introduction
99
100
106
106
106
4.7.1 Introduction
106
4.8.1 Introduction
108
108
108
109
..
113
..
115
..
119
107
106
....
120
120
120
121
122
126
129
5.6 Software ..
142
143
143
144
5.10 Documentation
..
144
144
5.12 Deliverables
..
....................................
145
159
Nomenclature:
Pitch angle
Yaw angle
Roll angle
ADC
AF
After cooler
AHS
AISI
ANSI
AOUT
Analog Out
API
ANALOG IN
Analog Input
ASME
ASTM
BS
British standards
BVIS
CCE
CD
Compact Disc
COTS
Commercially-off-the-shelf
CS
Carbon Steel
Diffuser
DAQ
Data Acquisition
DAC
Db
DER
Di
DIG IN
Digital IN
DIN
Digital IN
DIG OUT
Digital Out
DOUT
Digital Out
DMR
DN
Nominal diameter
DNV
Det-Norske Veritas
Ds
EGV
EH
Electro Hydraulic
EIL
EMI
EMC
EP
Electro Pneumatic
FCI
GUI
Heater
HMS
HP
High Pressure
HPS
HSV
HT
High Tension
HWT
INR
LEL
LPG
LRIS
LT
Low tension
Mach Number
MAWP
MBV
MCC
MCS
MFA
MICS
MIM
MS
Measurement System
MT
Metric tones
MTBF
MVWSS
Nozzle
NDT
NPS
OISD
P & ID
PDR
PID
PIV
PLIF
PM
Pressure Measurement
PP
Perforated plate
Pr
Pressure
PRCS
PRS
PRV
PSP
PT
Pressure Transducer
QAP
QC
Quality Control
Re
Reynolds Number
ROV
RT
Radiography Test
RTD
RTDAS
RTOS
RTJ
SC
Settling Chamber
SCADA
SNR
SS
Stainless Steel
STP
TC
Thermocouple
TEMA
TM
Temperature Measurement
TMR
TPIA
TS
Test Section
UPS
VG
Vacuum Gauge
VIV
VPV
VS
Vacuum System
VTA
Vent to Atmosphere
10
Table 1.1
Nomenclature
Description
Test medium
Air
1.0 m
Mach number
5, 6.5, 8, 10 and 12
10 - 100
346 -1400
0.01
0.7 - 180
20
Types of tests
* Run time - Useful test time excluding flow settling time of approximately 20 sec
Mach
P0
T0
P0
T0
(Bar)
(K)
(kg/sec)
(Bar)
(K)
(kg/sec)
30
376
180
10
346
61.38
6.5
100
575
152.4
10
487
16.6
100
760
60.6
10
653
6.5
10
100
1046
18.3
10
912
12
100
1377
6.7
10
1211
0.7
no
Note- Operating range of each Mach number is from lowest to highest. For example, Mach
5 nozzle will be operated in the range of stagnation pressure from 10 to 30bar. Other
nozzles (Mach 6.5, 8, 10 & 12) will be operated in the range of stagnation pressure from 10
to 100 bar.
11
M easurement system
Cooling towers
Vacuum
Pumps
Tunnel System
Compressors
Pressure regulating
system
High Pressure
storage tanks
Tunnel
Control system
Vacuum
spheres
HEATER
Nozzle Test
Diffuser
Section
Settling
chamber
M odel Incidence
M echanism
Hot shut
Fig. 1.1
Vacuum isolation
valve
After cooler
GL
Department shall mean and include the President of India acting through the
Director, DRDL and any representative (s) of the Department duly authorized on his
behalf.
Contractor shall mean the individual or firm or company whether incorporated or not,
chosen by the Department among the bidders to this tender enquiry, under-taking the
works and shall include the legal personal representatives of such individuals or the
persons composing such firm or company, of the successors of such firm or company
and the permitted assignee of such individual or firm (s) or company.
Contract shall mean the formal agreement to be executed between the President of
India and the bidder, whom the Department may choose, based on the documents
forming this tender enquiry and acceptance thereof by the bidder and together with the
documents as referred to therein including the specifications, designs, drawings and
instructions issued from time to time by the Department.
Site shall mean the land and or other places at Hyderabad on which work is to be
executed under the contract, which may be allotted by the Department for the purpose
of carrying out the work.
Materials shall mean all the items required for realizing and forming part of the Wind
Tunnel System, including raw materials, semi-finished & finished products and
subassemblies, which are manufactured by the Contractor or their sub-Contractors or
brought-out from their sub-Contractors, such as equipments, flow components, pipes,
pipe fittings, instruments, etc.
All the pressure values specified in this document are in absolute scale, unless
specified otherwise.
13
(ii)
(iii)
(iv)
Integration of sensors, instruments with wind tunnel systems and development and
supply of software for wind tunnel operation and control.
(v)
(vi)
Schlieren System will be supplied by other vendor. Wind Tunnel System vendor has
to keep provision for fixing glass windows on doors and top cover of Test Section.
(vii)
All civil works (except civil works associated with LPG system) will be carried out by
Department. Contractor has to provide all necessary details of foundation required
for installation of different components including any special foundations required for
heaters, test section, etc.
(viii) Contractor has to indicate total electrical power requirement including power
requirement for pumps for cooling systems, Department would provide only input
power to the Wind Tunnel Building from LT sub-station. Further distribution at
different points has to be done by the Contractor.
(ix)
Contractor has to specify total water requirement for cooling system. Utility water
(softened) will be provided by the Department at nearest point as specified by
Contractor. Contractor will be responsible for further routing of pipe at different
14
locations. However, the contractor has to specify the quantity and the quality of the
water required for various systems.
(x)
(xi)
Integration of Wind Tunnel Systems with High Pressure System and Vacuum System
on either side.
(xii)
Note- Wind Tunnel System vendor will be provided with detailed specifications and
layout of High Pressure System and Vacuum System which will be reviewed and
accepted by them.
1.2 DURATION
The complete work mentioned above shall be executed within a period of 48 months from
the date of signing the contract.
Tunnel System
The settling chamber is used to get a low-velocity, homogeneous flow free of turbulence. A
nozzle accelerates the air stream to the specified different speed. To get a given speed of
air stream, a unique nozzle configuration is employed. So, different nozzles are used to get
different speed of air stream. The test section contains the model to be characterized and
associated instrumentation. A diffuser decelerates the air from test section and air is
collected in the vacuum spheres. Vacuum pumps are used to evacuate the vacuum
spheres.
Tunnel system
Wind tunnel system is integrated to the High Pressure System in the upstream side
and Vacuum System in the downstream side. The high pressure system of block A and
the vacuum system of block D together generate the driving pressure ratio to establish
required test conditions in the test section.
High Pressure System - Block A of Fig. 1.2: The high pressure system consists of
storage tanks of 80 m3 capacity with storage pressure 300 bar and associated
compressors, driers, etc. The storage system is sized to cater the operating envelope of the
facility as given in Table 1.2 and can be recharged within 2 hrs.
Air Heating System Block B of Fig. 1.2: The air from the storage system is regulated for
the given pressure through a pressure regulating system during the test to meet that
specific test condition. This regulated air further passes through the air heating system to
avoid liquefaction of air at very low temperatures in the test section. The capacity of the air
heater caters for a mass flow variation of 0.7-180 kg/s and a temperature rise upto 1700 K.
Two heaters are proposed A bigger heater which can handle higher mass flow upto
180 Kg/sec and lower temperature (700 K) and a smaller heater which can handle mass
flow rate upto 60.6 Kg/sec and higher temperature (1700 K). Cored brick heaters will be
used. The air heating system consists of the main heater bed, a burner blower for
combustion and associated LPG storage system and a requisite control and safety
features.
Tunnel System Block C of Fig. 1.2: This is the main subsystem of the tunnel consisting
of settling chamber, set of nozzles, test section and supersonic and subsonic diffusers,
connecting duct and Aftercooler. The hypersonic test conditions are simulated in the test
section by the selection of specific nozzle and blowdown pressure and temperature
conditions. The tunnel system further requires a separate cooling system consisting of two
blocks - one to cater to cooling of tunnel components like nozzles, diffuser, etc and the
second to cater for the cooling of air at the exit of the diffuser. Into this system the main
tunnel control system has to be integrated for appropriate control of testing conditions and
various safety interlock requirements.
Vacuum System Block D of Fig. 1.2: In hypersonic testing due to the high pressure ratio
required for testing, a vacuum system is required in downstream. The vacuum system
17
consists of three spherical storage tanks of 2200 m3 capacity each with vacuum levels of
0.01 mbar. This is achieved using two chains of four stage vacuum pumps of requisite
capacity to meet cycle time requirements of 2 hrs.
Instrumentation and Control system Block E of Fig. 1.2: The Tunnel control system
consists of two levels of control with requisite health monitoring and sequencing. At the
lower level each major system viz. high pressure system, pressure regulating system, air
heating system, vacuum system, model injection system are monitored and controlled.
Required safety features are incorporated for each subsystem for proper functioning which
includes redundant measurements and fault tolerance. At the higher level, the main control
system of the tunnel takes care of health monitoring of the above subsystems, sequencing
of tunnel operation, safety and interface interlock of these subsystems. Both hardware and
software redundancy are expected to be built up for proper functioning of the tunnel system.
The model injection into the tunnel after establishment of the flow and the variation of model
attitude during the testing are achieved by Model Incidence Mechanism with its associated
actuators, controllers, software and DAQ. This system is interfaced appropriately with the
tunnel control system.
1.5
SCOPE OF CONTRACT
The scope of the contract and the demarcation of responsibilities between the Department
and the Contractor for realization of individual system are given in this section.
1.5.1.1
The conceptual design of the system has been done by the Department. In this document,
the P & ID along with tentative sizes of the fluid circuits for PRV system, tentative sizes of
other tunnel components are given. All the necessary input parameters (pressure,
temperature, mass flow rate) have been defined. Technical specification of individual
system has been provided in respective chapter. These details are given only for price
estimation. There may be changes in size etc. based on the design carried out by the
Contractor. The Contractor shall carry out preliminary design of the system within a period
of two months. The design done by the Contractor shall be reviewed and approved by the
Department. Department shall organize the Preliminary Design Review (PDR) meeting at
the Department within a period of one month from the receipt of design report with all
relevant details from the Contractor.
1.5.1.2
EQUIPMENT LAY-OUT
The location plan and equipment lay-out of all the systems are given in this document.
Based on this equipment layout and the P & ID, the Contractor shall prepare lay-out of
pipeline and other tunnel component, prepare isometric drawings and derive the actual
lengths required to connect between the various interfaces.
1.5.1.3
Upon award of the contract and after Preliminary Design Review, the Contractor shall carry
out detailed engineering. The Department will review the detailed engineering done by the
Contractor.
1.5.1.4
The Department will carry out the following major civil works:
Tunnel building, heater shed, Shed for Pressure Regulating System, etc
However, the Contractor shall provide the details of the area required, loads on the
equipments foundations etc.
Note: All civil works associated with the LPG system should be carried out by the
vendor.
19
1.5.1.5
During erection and commissioning, the Department will provide the following services:
Electricity for erection on chargeable basis at the tariff rate prevailing at the time
of consumption
1.5.1.6
ELECTRICAL SYSTEM
Department would provide only input power with open ended cable to the Wind Tunnel
Building ground floor panel room from LT sub-station. Further distribution at different points
have to be done by the Contractor. The contractor has to provide main distribution panel
with necessary switchgear at panel room and also set up the local distribution panels near
to the respective load center wherever required. All equipments should have power
disconnection option locally.
between distribution panels as per IS 7098 standard, PVC insulated copper cable between
panels and equipments as per IS 1554 standard) is in the contractor scope. Connection
between distribution panels and earth pits is in the contractor scope.
Contractor has to indicate total electrical power requirement which should cover the
connected load, running load of individual subsystems and layout of the cable routing.
1.5.1.7
WATER SUPPLY
Contractor has to specify total water requirement for cooling system. Utility water will be
provided by the Department at nearest point as specified by Contractor. Contractor will be
responsible for further routing of pipe at different locations.
20
Design of Wind Tunnel System to comply with the specified functional requirements
as given in respective chapter of this document.
c. Detailed mechanical design of all the tunnel components will be carried out and
fabrication drawings will be prepared.
d. The detailed Quality Assurance Plan (QAP) for the materials such as pipes, pipe
fittings,
valves,
tunnel
components,
instruments,
fabrication,
erection
and
procedure
and
acceptance
criteria
for
fabrication,
erection
and
The list of sub-vendors along with their company profile, technical catalogues etc.
from whom the Contractor has finalized to purchase the materials such as
equipments, tunnel components, instruments, pipes, pipe fittings, valves, etc. shall
be provided.
j.
The Contractor shall provide Detailed Engineering Review (DER) document within 4
months after PDR approval. Department will arrange Detailed Engineering Review (DER)
meeting at the Departments site within two weeks after the submission of document.
Contractors representative (s) will participate in DER.
1.5.2.3
SELECTION OF SUB-CONTRACTORS
The list of sub-Contractors, if any, through whom the bidder proposes to acquire the
material and services for the execution of work, shall be given in the quotation. The list of
sub-Contractors proposed by the bidder is subject to review by the Department during
evaluation of the quotation.
22
During DER, the Contractor shall submit the final list of sub-Contractors with whom they
have finalized to purchase the materials and services. This list of sub-Contractors, along
with the purchase specification, is subject to review and approval by the Department.
1.5.2.4
PURCHASE OF MATERIALS
All the bought out items and materials for individual system are to be purchased by the
Contractor as per approved QA plan. The Contractor shall purchase the subsystem/materials as per specified source, wherever applicable. The purchase specifications
of such items and the sub-vendors from whom such materials are to be purchased are
subject to review and approval by the Department.
1.5.2.5
SUPPLY OF SPARES
All the necessary spares pertaining to respective system shall be supplied by the
Contractor along with the system. Detailed spares required for individual system is given in
respective chapter. The break-up prices of the spares shall be given in the quotation.
1.5.2.6
FABRICATION
The system shall be fabricated at the Contractors factory to such an extent that they can be
transported by sea and road. The fabrication shall include testing & cleaning of the system.
All the consumables, tools, tackle; etc required for fabrication shall be arranged by the
Contractor.
1.5.2.7
INSPECTION
All the bought-out materials, fabrication drawings and the works during fabrication at the
Contractors factory and erection at the Departments site shall be inspected by one of the
following reputed Third Party Inspection Agencies (TPIA).
TPIA will be involved for design clearance, fabrication, inspection and acceptance. The
detailed scope of inspection shall be prepared by the Contractor and approved by the
Department. It shall be the Contractors responsibility to arrange for and co-ordinate with
the TPIA. The price ceiling for inspection by the TPIA shall be separately mentioned in the
quotation. However, the payment of price for inspection shall be made only to the extent
23
and upon production of invoice by the TPIA, subject to the ceiling to be mentioned in the
contract. Apart from inspection by the TPIA, the Departments representative(s) shall
inspect the system at any stage of fabrication and erection.
1.5.2.8
TRANSPORTATION
All the fabricated items and bought out materials shall be properly packed and transported
to the Departments site at Hyderabad.
1.5.2.9
ERECTION
The system is to be erected by the Contractor at the Departments site. Apart from erecting
the system fabricated by the Contractor, it shall also be the Contractors responsibility to
erect the major equipments supplied by the Contractor. The work done by the Contractor
during erection shall be inspected by the TPIA. The erection shall also include cleaning &
testing, minor civil & structural works (for grounding of equipments, pipe supports, access
bridges, platforms, staircase, etc), and electrical system in and from MCC.
The Contractor shall arrange for constructing temporary sheds/ buildings for storing
materials, erection equipments, tools & tackles, etc. The Contractors personnel shall not be
permitted to reside inside the Departments premises after the work. The Contractor shall
arrange for transportation, accommodation, food, health care, communication, etc for their
personnel.
1.5.2.10 COMMISSIONING
Each system shall be commissioned by the Contractor in two phases as follows:
In the first phase all the subsystems of individual system will be tested individually,
in static (no-flow) condition.
In the second phase, individual system will be tested with the rest of the tunnel
system in integrated way.
The entire tunnel will be deemed to be commissioned when four successful tests have been
conducted for each Mach number at the maximum pressure and temperature condition for
a steady duration of minimum 20 seconds.
1.5.2.11 DOCUMENTATION
The Contractor shall prepare the relevant documents during different phases of the
Contract. All the documents shall be provided in 3 copies in English language only. In the
event that the documents by the sub-vendors/ sub-Contractors are in some other language,
24
25
BLOCK - A
BLOCK - B
BURNER
SYSTEM
VALVE OPERATING
SYSTEM
BLOCK - C
VENT
CHIMNEY
COOLING WATER
SYSTEM
HSV5
PRV3
HSV7
M = 10 & 12
EGV7
MBV3
SETTLING
M = 5 & 6.5
EGV4
EGV5
PRV1
M = 5 & 6.5
TEST SECTION
HSV2
HSV1
PRV2
M=8
COOLER
VIV
M = 8, 10 & 12
VACUUM
H2
MBV2
SPHERE
HSV4
HSV3
HSV8
EGV6
HSV6
SYSTEM
AFTER
H1
M = 8, 10 & 12
HIGH PRESSURE
SCHLIEREN &
I R SYSTEM
CHAMBER1
MBV1
STORAGE
M = 5 & 6.5
BLOCK -D
SETTLING
CHAMBER2
NOZZLE
VENT
CHIMNEY
DIFFUSER
VACUUM
SYSTEM
MIM
SYSTEM
ELECTRICAL
SYSTEM
MIM
TEST SECTION
EVACUATION
SYSTEM
BLOCK - E
TC 3
TC 2
TC 1
TC 4
TC MAIN
BLOCK
BLOCK
BLOCK
BLOCK
BLOCK
TC
HSV
PRV
VIV
MBV
:Tunnel CONTROL
: Hot Shutoff Valve
: Pressure Regulating Valve
: Vacuum Isolation Valve
: Manual Ball Valve
26
150m
Heater 1
Compressors
Heater 2
High Pressure
storage tanks
300m
CHIMNEY
EXPANSION
BELLOW
DIFFUSER
TEST
SECTION
CONNECTING
DUCT
VACUUM
SHPERE
PRS
NOZZLE
SETTLING
CHAMBER
HEATER SHED WITH
HEATER AND PLATFORM
AIR STORAGE
Actuators
Servo valves
Sensors
The preliminary layout along with the preliminary sizes of the fluid circuits and an
indicative layout of the facility are given in this document. The details of Contractors
scope of work shall include the following:
Purchase of all materials such as manual valves, globe valve, pressure regulating
valve, actuators, power packs, servo valves, instruments, pipes, pipe fittings, etc.
Fabrication, testing and co-ordination for inspection of the system at the Contractors
factory.
Erection, testing and co-ordination for inspection of the entire system at the
Departments site.
29
2.1
Arrangement of PRS is shown in Fig. 2.1. The location of PRS with adjacent systems is
given in Fig. 2.2. A preliminary P & ID of the PRS is given in Fig. 2.3.
The system comprises of the following:
Three numbers of Globe type Pressure Regulating Valves having nominal size 2, 4
and 12 with associated actuators, power pack, servo valves, pressure transducers,
positioner, etc.
Fluid Circuit & Interface-The fluid circuit connects various subsystems of Pressure
Regulating Valve to air storage vessels in upstream and heater in downstream side.
Fluid circuit consists of various flow components like manual valves, electropneumatic (EP) valve/ electro-hydraulic (EH) valve, associated pipe line, pressure
gauges, safety devices, etc.
PRS shall be designed for the input pressure range of 300 -100 bar.
Tests are planned at five different Mach numbers. For each Mach number condition,
tests will be conducted at different pressure level in the settling chamber. The range of
operating pressure and mass flow rate for each Mach number operation is given in
Table 2.1. During the test, system will be operated for any pressure between the
minimum to maximum. For a given test, the settling chamber pressure is fixed.
The pressure at the settling chamber shall be controlled within 1% of the set pressure
in a closed loop.
The Contractor shall design the PRS having optimum sizes and number of PRV, to
meet the above requirements (Tentative list of PRV is given in the Table 2.2). Each
control valve shall be isolated downstream by manual ball valve and upstream by an
electro-pneumatic/electro-hydraulic globe valve. (Tentative list is given in the Table 2.3
& Table 2.4)
30
Table 2.1 : Operating pressure and mass flow rates required at different test
conditions
Settling chamber
Pressure (Bar)
2.2
Mach 6.5
Mach 8
Mach 10
Mach 12
10
61.38
16.57
6.54
1.96
0.7
20
119.55
32.38
12.80
3.85
1.40
30
180
47.87
18.94
5.70
2.08
40
63.17
25.02
7.54
2.75
50
78.31
31.04
9.36
3.42
60
93.33
37.02
11.17
4.08
70
108.25
42.96
12.97
4.74
80
123.08
48.86
14.76
5.40
90
137.84
54.74
16.54
6.05
100
152.40
60.60
18.31
6.71
SCOPE OF WORK
2.2.1 DESIGN
I. The design of the system, sub-system and the components shall be done to meet the
specifications and the functional requirements specified in the document.
II. The design shall be based on the standards/codes mentioned in Table 2.5 and if an
equivalent/better practices are followed, the same shall be informed in advance to the
department and the approval shall be obtained.
III. The design shall be analyzed for the critical conditions and the soundness shall be
established with adequate factor of safety.
IV. Adequate redundancy shall be considered while designing the system.
V. The details of the design and analysis carried out by the Contractor shall be
documented and produced whenever required.
VI. The system design and analysis will be reviewed and approved by the mutually
agreed third party inspection agency (TPIA) like LRIS, BVQI or any other Govt.
approved agency. The design shall be scrutinized and approved by the Department,
before taking up the realization/procurement.
31
VII. Material specifications, their form, condition and acceptance criteria shall be brought
out in the design.
VIII. Weld joints details, RT & DPT acceptance, internal surface finish, details of support
structure, foundation and erection shall be clearly mentioned and presented to the
Department with the approval of third party.
IX.The Detailed Quality Assurance Plan (QAP) will be prepared based on mutual
discussion with the vendor.
X. During the design phase any change in the design input (major/minor) shall be
accepted by the Contractor and incorporated.
XI. If need arises, the Department may involve and interact during the deliberations
between the Contractor and TPIA.
XII. However, it is the responsibility of the Contractor to ensure the soundness of the
design to meet the functional requirements of the systems.
2.2.2 MATERIAL
a. Qualified material shall only be used for fabricating the components.
b. Material shall be identified for each component and the traceability shall be ensured.
c. Each batch of material shall undergo testing in terms of chemical composition,
mechanical properties under the surveillance of mutually agreed third party inspection
agency (TPIA) like LRIS, BVQI, DNV, or any other Govt. approved agencies.
d. The material to be used for realization of PRS shall be purchased from approved
vendors/ manufacturers. The list of vendors/ manufacturers shall be furnished to
Department for approval.
2.2.3
FABRICATION
a. Fabrication of the components shall commence only after approval of the design by
the Department
b. Before commencing the fabrication, the Contractor shall prepare the detailed
fabrication process drawings, process plan, and quality control plan and get the
approval from the TPIA prior to submission to Department for review and approval.
c. All the welding shall be done by qualified welders only. Welders qualification shall
be done in accordance with ASME section IX, under the surveillance of TPIA
d. All the weld joints shall be qualified in accordance with ASME code section IX
e. Suitable process shall be evolved, for relieving the stresses on welded joints.
32
Details shall be furnished regarding the proposed scheme of stress relieving in the
process plan.
f. Considering the size of the system, the Contractor shall plan and schedule the
fabrication activities at the erection side also, in the department. The Contractor shall
indicate electrical power requirements for the work, which shall be made available
on chargeable basis.
g. The Contractor shall make arrangements for necessary fabrication equipments
including handling for site work at the Departments premises.
h. The Contractor shall agree to accommodate minor changes, if any, during the course
of fabrication.
2.2.4 INSPECTION
The broad scope of inspection shall be as follows. However, the detailed scope of
inspection shall be given in the quotation.
a. Review of the fabrication drawings for fluid circuits
b. Identification of the materials such as equipments, flow components, instruments, pipes,
pipe fittings, etc and review of the test and calibration certificates for compliance with the
contract specification.
c. Witnessing of welding procedure qualification and welders performance qualification
tests. If the welders already possess the performance certificate, the TPIA shall review
and authorize the same.
d. Review of X-ray films of radio-graphic tests for possible defects in the weld joints.
e. Inspection at any stage of fabrication to ensure that the methodology employed for
fabrication is in compliance with the requirements of standards/ codes, practices,
contract specification and the approved documents.
f. Witnessing of pressure test, leak test and cleanliness test of the system during
fabrication and erection at site.
II.
2.2.6 ERECTION
The system is to be erected by the Contractor at the Departments site. Apart from erecting
the system fabricated by the Contractor, it shall also be the Contractors responsibility to
erect the components supplied by the Contractor. The work done by the Contractor during
erection shall be inspected by the TPI agency. The erection shall also include cleaning &
testing, minor civil & structural works.
The Contractor shall arrange for constructing temporary sheds/ buildings for storing
materials of PRS, piping, erection equipments, tools & tackles, etc. The Contractors
personnel shall not be permitted to reside inside the Departments premises after the work.
The Contractor shall arrange for transportation, accommodation, food, health care,
communication, safety etc for their personnel.
2.2.7 COMMISSIONING
The pressure regulating system shall be commissioned by the Contractor in two phases as
follows:
In the first phase all the subsystems/components of PRS shall be tested individually.
In the second phase, PRS shall be tested with the rest of the tunnel system in integrated
way.
Major Acceptance tests have been mentioned in the document. However, a detailed
mutually agreed Acceptance Test Plan (ATP) document will be prepared by vendor and
Department during Detailed Engineering Review (DER).
34
2.3
SPECIFICATIONS
(Tag no., Working Temperature range, MAWP, Indicative Valve Size as given in
Table 2.2 & Fig 2.3)
Design code
ANSI B 16.34
Test code
Material (body)
Pressure class
Class 2500
End connection
Size
2, 4 and 12
Trim characteristics
Working temperature
200-310K
330 bar
seat
: 1% of set pressure
Run time
40 sec.
Control algorithm
Three level
Safety
Fail to close
Allowable noise
Actuator
Make
Fisher
The other specifications and tests shall be the same as those given for Manual valves and
Electro-pneumatic valve.
35
Table 2.2
Valve
Type of valve
Temperature
MAWP
(K)
(MPa)
PRV1
200-310
33
12
Globe
PRV2
200-310
33
Globe
PRV3
200-310
33
Globe
Tag no.
(Inches)
i) LIMIT SWITCHES
Suitable limit switches shall be provided for indicating the extreme position of the
valve (i.e. fully open or Fully closed condition). Triple mode redundancy is required for
these sensors.
Temperature (K)
Nominal Valve
MAWP
Size (Inches)
Type of valve
(MPa)
MBV1
200-310
33
12
Ball
MBV2
200-310
33
Ball
MBV3
200-310
33
Ball
Tag no, pattern, working temperature range, Size, MAWP are given above in Table 2.3
Actuation
Application
Isolation
36
2. Bubble tight as per API 598 or Rate A as per API 598 or Rate A of BS 6755 part1 for
gate, ball and butterfly valves
End connection
Style of construction
Body
connections
Bonnet
Stem
Plug
Seat
Flow direction
Flow to open
Cycle of operation
10,000 cycles
MOC (Body)
Design code
Test code
Suitable limit switches shall be provided for indicating the extreme position of the valve (i.e,
fully open & fully closed position)
Electro-pneumatically/Electromechanically operated
(Tag no., working Temperature range, Size, MAWP As given in Table 2.4)
Table 2.4
Valve
Tag no.
Nominal
Type of
Mode of
Valve size
valve
Operation
(K)
(MPa)
(Inches)
EGV5
200-310
33
12
Globe
EP/EH
EGV6
200-310
33
Globe
EP/EH
EGV7
200-310
33
Globe
EP/EH
37
ii) Actuator
Type
Safety
Fail to close.
Response time
< 5 sec
Body material
Hard-anodized Aluminum
Solenoid Valves
Suitable solenoid valve with service gas air and excitation Voltage of 24 V. Solenoid valves
are to be configured as triple mode redundancy.
iii) Limit Switches
It should have suitable limit switches with proper electrical conduit and are to be configured
as triple mode redundancy.
2.3.4 PIPES
The details of pipe line connecting the high-pressure system (HPS) and Air heater is given
in layout. The PRS shall be connected to EGV4 of HPS as given in Fig.2.1. Wind Tunnel
Building is located away from the wind tunnel building in view of safety considerations. The
required length of the pipeline will be worked out accordingly.
Type
seamless pipes
as per P & ID
Length
Material
Dimensional standard
ANSI B 36.19/36.10
Type
Flanges
ANSI B 16.5
ANSI B 16.9
ANSI B 16.11
Flanges
2.4
ACCEPTANCE TESTS
2.4.1 VALVES
a) Material certificate: The material test certificates, detailing the physical and chemical
properties of the principle pressure-bearing parts shall be provided.
b) Welding joints test: Any butt welding joints in the valve shall be subjected to radiographic test with X-rays or gamma rays to 2-T sensitivity.
c) Soundness test for casting: All the casting shall be subjected to soundness test with
radio-graphic or ultra-sonic technique for flaw detection.
d) Hydraulic shell pressure test: The valve, prior to assembly with the bellows in partially
open position, shall be subjected to pressure test with water (with suitable corrosion
inhibitor) at the maximum rated working pressure as per standard. The test procedure
and acceptance criteria shall be as per BS 6755 Part1 or API 598 or ANSI B 16.34.
e) Hydraulic seat pressure test: The valve, in closed position, shall be subjected to
pressure test with water (with suitable corrosion inhibitor) at the maximum rated working
pressure as per standard. The test procedure and acceptance criteria shall be as per
BS 6755 Part 1 or API 598 or ANSI B 16.34.
f) Pneumatic seat test (for ball valve only): The leak rate across the seat of ball valves
shall be tested with dry air at 0.4 to 0.7 MPa by water displacement (bubble) method.
The acceptance criteria shall be as per BS 6775 Part1 or API598 or ANSI B 16.34.
g) Functional test: The valve with all accessories mounted shall be subjected to functional
test to validate the performance.
h) Marking: All the valves are assigned tag numbers for the sake of identification. The
tag number for each valve, as indicated above, besides size, pressure rating class,
material of construction etc. shall be engraved on the body of the valves.
39
2.4.2 PIPES
The following tests are to be conducted on the pipes:
i) Visual examination: All the pipes shall be visually examined for workmanship.
ii) Dimensional check: One specimen from each lot shall be subjected to dimensional
check.
iii) Chemical analysis:
40
2.4.4 CLEANING
The fabricated SS pipe-lines shall be cleaned as per the following procedure:
a. Mechanical cleaning: All the metallic surfaces with scales and newly welded surfaces
will be cleaned by scrubbing with SS wire brush. The loose particles generated by
mechanical cleaning shall be removed by blowing with compressed air, sucking or
washing with water.
b. Degreasing : The oil and grease adherent to the surface shall be removed by vapour
phase de-greasing with Tri Chloro Ethylene (TCE) or Per Chloro Ethylene (PCE),
followed by liquid phase de-greasing with TCE or PCE.
c. Pickling: In order to remove rusts and scales, the surfaces shall be washed with water
and pickled with a solution containing Hydro-fluoric acid (HF) and Nitric acid (HNO3).
The composition of the pickling solution and duration are to be adjusted after trial test on
a sample piece to remove uniformly less than 25m thick material. Mostly, the
composition is as follows;
HF
5% by mass
HNO3
15 to 20 %
Water
Remainder
HNO3
25% by volume
Water
Remainder
Duration
2h
2.4.5 PAINTING
All the CS pipe-lines and non-insulated SS pipe-lines shall be painted based on the colour
code scheme. All the pipe-lines, flow components and instruments shall be provided with
identification name plate displaying in bold letters, their tag numbers. All the structural
materials shall be painted in gray colour and stairs handrails in yellow colour. The color
code scheme shall be provided upon award of the contract. Prior to painting, the surfaces
shall be suitably prepared. The painting shall comprise 2 coats of primer and 2 coats of
synthetic enamel.
41
2.5
FUNCTIONAL TEST
2.6
DOCUMENTATION
42
2.6.3 FABRICATION
a. As built fabrication drawings.
b. Test certificates and inspection reports of the materials such as equipments, flow
components, pipes, pipe fittings, instruments (including the calibration certificates), etc.
c. Wiring diagram of instrumentation and electrical systems.
d. Test certificates and inspection reports of fabrication (including the radiographic films)
2.6.4 ERECTION
At the end of erection, the following documents shall be submitted.
a. As-built pipe-line layout drawings.
b. As-built pipe-line isometric drawings.
c. As-built cable layout drawings.
d. Estimation of pressure drop based on the as-built pipe-line isometric drawings.
e. Certificates of tests (including radiographic films) done during erection.
f. Inspection report by the Department
Standard/code
Piping
ANSI B 31.3/31.1
SS pipes
ANSI B 36.19
CS pipes
ANSI B 36.10
ANSI B 16.9
ANSI B 16.11
Flanges
ANSI B 16.5
Gaskets
Ball valves
Globe/Needle valves
Pressure regulators
Manufacturers standard
Filters
Manufacturers standard
43
API RP 527
Pressure gauges
BS 1780/IS 3624
ASTM A 530
ASTM A 380
NDT
ASME Section V
Welding
Radiography
ASTM E 94
2.7
DELIVERABLES
The deliverables for the Pressure Regulation system is given in Table 2.6
Table 2.6
: List of Deliverables
Sr.
Item
no.
1.
2.
3.
4.
Qty.
+ 3 nos
3 nos.
( 1 each)
3 nos.
( 1 each)
1 no.
1 no.
44
1 no.
MBV2
PRV2
EGV6
4 branch
pipe
MBV1
PRV1
MBV3
EGV5
PRV3
EGV 4
(Part of
HPS)
Fig. 2.1
EGV7
45
2 branch
pipe
Pressure
regulating
system
Settling
chamber
Air
heater
Air
storage
Fig. 2.2
Nozzle
Test
Section
Fig. 2.3
47
48
Heater bed
Distributor
Low pressure air supply and storage system for mixing (diluting) air
High pressure and High temperature valves (hot Shut-off valves) with associated
pipe lines
Foundations and Supporting structures for heater, all valves and all pipe lines
Safety devices
Pressure sensors
Flow measurements
Electrical System
Transient thermal analysis, thermo structural analysis for heater, piping etc.
Fabrication, testing and co-ordination for inspection of the system at the Contractors
factory.
Erection, testing and co-ordination for inspection of the entire system at the
Departments site.
Commissioning of AHS.
50
Fig. 3.1
51
Fig. 3.2
This will reduce the design temperature (order of 333 K) of the distributor (which is
discussed below) and the hot combustion gas from the bed shall be exhausted through
ducting to chimney. However, the thermal gradient should not affect the performance of the
bed to deliver the required air temperature during tunnel blowdown.
The bed should have the following quality for 10,000 cycles of operation:
(i) Thermal shock withstanding quality
(ii) Abrasive resistance capacity to avoid dust formation.
Table 3.1
Mass
Operating
Stagnation
Stagnation
Mach
Pressure
Temperature
number
(bar)
(K)
5L
10
346
446
61.38
20
364
464
119.55
5H
30
376
476
180
6.5 L
10
487
637
16.57
6.5
20
510
660
32.38
6.5
30
525
675
47.87
6.5
40
536
686
63.17
6.5
50
545
695
78.31
6.5
60
553
703
93.33
10
6.5
70
559
709
108.25
11
6.5
80
565
715
123.08
12
6.5
90
570
720
137.84
13
6.5 H
100
575
725
152.40
Sl.
No.
Exit Air
Temperature
(K)*
flow rate
(kg/sec)
Heater 2
Operating
Stagnation
Stagnation
Heater
Mass
Mach
Pressure
Temperature
Exit Air
flow rate
number
(bar)
(K)
Temperature (K)
(kg/sec)
14
8L
10
653
903
6.54
15
20
682
932
12.80
16
30
700
950
18.94
17
40
714
964
25.02
Sl.
No.
53
18
50
725
975
31.04
19
60
734
984
37.02
20
70
742
992
42.96
21
80
749
999
48.86
22
90
755
1005
54.74
23
8H
100
760
1010
60.60
24
10 L
10
912
1212
1.96
25
10
20
949
1249
3.85
26
10
30
972
1272
5.70
27
10
40
989
1289
7.54
28
10
50
1003
1303
9.36
29
10
60
1014
1314
11.17
30
10
70
1024
1324
12.97
31
10
80
1033
1333
14.76
32
10
90
1041
1341
16.54
33
10 H
100
1048
1348
18.31
34
12 L
10
1211
1511
0.72
35
12
20
1257
1557
1.40
36
12
30
1286
1586
2.08
37
12
40
1306
1606
2.75
38
12
50
1323
1623
3.42
39
12
60
1337
1637
4.08
40
12
70
1349
1649
4.74
41
12
80
1360
1660
5.40
42
12
90
1369
1669
6.05
43
12 H
100
1378
1678
6.71
*Note - Only approximate temperature is specified. The contractor need to carry out
detailed analysis and estimate the temperature drop from heater to settling chamber and
accordingly finalize the heater exit temperature.
54
Table 3.2
Sl
no.
Heater-1
Heater2
Operation of Heater
Intermittent
Intermittent
Fuel
LPG
LPG
200 - 300 K
200-300 K
700 + 50 K
1700 + 50 K
13 MPa
13 MPa
10 Kpa
180 kg/sec
60.6 kg/sec
333 K
333 K
10
10,000 cycles
10,000 cycles
11
Charging time
8h
8h
12
Recharging time
2h
2h
13
40 s
40 s
15
ASME
code
and ASME
relevant standards
code
and
relevant standards
: 13MPa
Design temperature
: 333 K
Design code
Material
The liner bricks and heater vessel integrity shall be ensured by the Contractor.
55
3.3.5 DISTRIBUTOR
A conical passage with a grid plate with perforations shall be provided at the bottom of the
bed to uniformly distribute the incoming flow from the 12 pipeline. The conical angle shall
be decided to ensure uniform flow distribution in the heater bed. The pressure drop across
the distributor should be of the order of 10 kPa. The distributor shall be designed to
withstand the weight of the heater bed, thermal shock and the temperature of the bottom
layer of the heater bed.
3.3.6 INTERFACE
Heaters will be integrated with 12 pipeline both in upstream and downstream.
condensed water inside the air heater after completion of heating cycle/recharge cycle are
to be evacuated through this line. This vent pipe shall be ducted outside the building.
3.3.8 BURNER-BLOWER
Burner Type: LPG based
The design of the burner shall consider means, not to contaminate the bed. Combustion
gas temperature will be depending upon the test requirement heating duraton: 8 hours
(from ambient temperature to 700 K and 1700 K in Heater 1 and Heater 2 respectively)
56
The Contractor shall work out the temperature loss of the bed after each blowdown and
shall ensure that the burner-blower is capable of reheating the bed to the required
temperature within 2 hours. The combustion gas has to be sent from top to bottom of the
bed. The combustion inside heater has to take place at designed combustion pressure.
The burners are to be isolated during blowdown time. The suitable valves are provided to
isolate the LPG line and air lines during blowdown time.
Two options can be considered for the burner design
Option 1: The burner shall be capable of burning at various air-fuel ratios so as to
achieve different exhaust temperatures of the hot combustion gases required
during the heating of the bed.
Option 2: The burner, which can burn at constant air-fuel ratio with a provision to mix air
with the combustion gases to attain the required temperature.
The burner-blower can be located either on the top of the heater vessel or outside the
heater in a separate room. The Contractor shall decide the location of the burner-blower
taking into account the technical viability and cost of operation.
The motor / compressor required for the burner-blower shall be supplied along with the
burner-blower. Contractor should also ensure that the exhaust gas composition should not
violate the pollution control norms.
3.3.9
The LPG storage tanks will be designed by the Contractor. These tanks shall be located
outside the building at a minimum distance of 30 m which meets the safety criteria. A
tentative specification of the system has been given for reference. It comprises of various
sub-systems as described below.
3.3.9.1
The LPG unloading system is intended to unload both liquid and vaporized LPG from LPG
tanker to the LPG storage bullet.
3.3.9.2
The LPG storage system consists of two nos. of LPG bullet having tentative storage
capacity of 60 MT each which will meet the requirement of 100 cycles of operation at
maximum consumption rate. Each bullet stores LPG at 17 bar. The LPG filling ends of the
vessels are connected by piping to LPG unloading system. The withdrawal ends are
connected to the LPG supply system. Necessary manual isolation valves will be provided at
57
the filling and withdrawal sides. Each storage bullet is provided with four nos of safety relief
devices. Each device is set at pressure difference of 0.5 bar. The outlets from the safety
devices are routed to a safe location for discharge to the atmosphere.
3.3.9.3
VAPORISER
The vaporizer is required to convert liquid LPG to vapour form and supply vaporized LPG at
required pressure to burner. The vaporizer will have sufficient flow rate required by the
heater burner and at required pressure. The conversion shall be accomplished by heating
the LPG by electric or steam.
3.3.9.4
The pressure regulating device is intended to regulate the mass flow of LPG at required
supply pressure at heater end. The pressure regulating system shall consist of electro
pneumatically operated globe valve. The system shall be capable to provide varying mass
flow and required pressure.
3.3.9.5
Medium Velocity Water Spray Sprinkler (MVWSS) system is intended to reduce tank
pressure by showering of water on the tank. The fire fighting system consists of LPG
leakage detectors, flame detectors, fire fighting nozzle and early warning for gas
concentration below the LEL (lower explosive limit). The detectors for the gas monitoring
system are strategically located at all facilities close to potential source of leakage. The
detection control equipment is provided in the control room for continuous monitoring even
during power failure. The water source point for sprinkler and fire fighting system shall be
provided by Department. However, the Contractor has to carry out necessary routing in the
LPG yard.
3.3.9.6
The LPG piping connects various subsystems/equipments of LPG bulk storage facility like
LPG unloading system, storage vessels and LPG supply system. Water piping is used in
sprinkler system & fire fighting system. Fluid circuits involve various flow components like
manual valves, electro-pneumatic (EP) valve, pressure gauges, safety devices etc. Pipes,
fittings and flow components are to be provided. The piping (approximate length-80 m) for
connecting LPG system to burner of air heating system is in the scope of contractor.
58
3.3.9.7
ELECTRICAL SYSTEM
The electrical system is intended to supply electrical power to the pumps, vaporizer and
other systems of LPG bulk storage. The systems include field panels, starters, circuit
breakers, switches, protective devices, cabling, earthing and all necessary HT & LT switch
gear as per OISD standard. All Lighting / electrical equipment and instrumentation inside
the Yard are flameproof conforming to IS: 2206 (Part I) and IS:2148 Standards.
The contractor shall furnish the electrical power requirement of various subsystems. The
Department shall provide electrical power with open-ended cable at the heater shed. Proper
routing & terminating of power cables at various equipments with necessary protective
devices is in the contractor scope. The department shall provide earth pits of 1.0 for
electronic instruments and 5 for mechanical equipments. However, proper routing &
connecting of mechanical/electronic equipments with the earth pits is in the contractor
scope. The contractor shall furnish the details regarding number of earth pits required & its
locations for connecting to mechanical & electronic equipments.
3.3.9.8
GENERAL REQUIREMENTS
1. Design of the LPG Storage Installation will be done in accordance with Oil Industry
Safety Directorate (OISD) standard.
2. All safety and fire fighting measures, which are required as per above norms, would be
put in place in the storage and handling area.
3. Entire operation of the LPG/Propane Bulk Storage Installation (except for decanting
from tankers) will be done remotely from a Central Control Room.
4. Suitable number of firewater facilities should be designed and provided as per OISD
guidelines.
5. Pipelines and terminal design should take into consideration the seismicity.
6. All lighting / electrical equipment and instrumentation inside the Yard are flameproof
conforming to IS: 2206 (Part I) and IS: 2148 Standards.
7. LPG unloading will be done through suitable pumps for liquid transfer and vapour
recovery compressors for vapour recovery. All pumps and compressors are fitted with
flame-proof motors.
8. Distribution of LPG from bullets shall be executed through
(a) Natural vapour stream; and
(b) Vaporisers
9. The LPG/Propane bulk storage and distribution should be automated and will comprise
of
59
Note: All civil works associated with the LPG system should be carried out by the
vendor.
3.3.10 CHIMNEY
A chimney shall be provided by the Contractor to vent out the combustion gases above the
tunnel building after blowing through the heater. The height of the chimney shall be such
that natural draught occurs. Necessary protection shall be provided by the Contractor to
avoid rainwater entry into the chimney.
60
Each heater will have 4nos. of hot shut-off valves (HSV). Schematic layout of hot shutoff
valve is given in Fig. 3.3 and specifications of hot shutoff valve are Table 3.3. The
functional requirement of the HSV is to isolate the heater from the pressure regulating
system upstream and tunnel system downstream, which will encounter a very high pressure
and high temperature. The main functions of the HSVs are as follows:
HSV1 and HSV3 - isolate the heater 1 and 2 from the pressure regulating system.
HSV2 and HSV 4- isolate the heater 1 and 2 from the settling chamber.
HSV5 and HSV6 - isolate the chimney from the heater system 1 and 2 during
blowdown.
HSV7 and HSV8 - isolate the heater 1 and 2 from vent pipe.
The most important aspect is the response time. For HSV2 and HSV4, the maximum
time allowed for full opening from fully closed condition is less than 3 seconds. These
two valves have to be fully opened in the shortest possible time. This is to ensure that
the minimum amount of air gets dumped into the vacuum vessels from the time the
valve starts opening to the fully open condition.
The typical heating cycle time from ambient bed temperature will be 8 hrs and Blowdown
time is 40 sec.
61
Fig. 3.3
62
Table 3.3
Application
End connection
Permissible leak rate
Flow direction
Min. operation Life
Safety
Heater-1
Size(mm)
Valve position
Tempreture
Pressure
Valve position
Tempreture (Flow)
Response time
Pressure(MAWP)
HSV1
300
During heating cycle
Closed
Heater side
PRV side
700 K
Ambient
2 bar
Ambient
During Blow Down
Open
150-300K
Less than 10 sec.
130 bar
HSV2
300
HSV5
300
Operating conditions
During heating cycle
During Blow Down
Closed
Closed
Heater side
Tunnel side
Heater side
Chimney side
700 K
Ambient
<700 K
Ambient
2 bar
0.1mbar(Vacuum)
130 bar
Ambient
During Blow Down
During heating cycle
Open
Open
700 K
700 K
Less than 3 sec.
Less than 10 sec.
130 bar
2 bar
HSV7
200
During heating cycle
Closed
Heater side
Vent side
700 K
Ambient
2 bar
Ambient
Blow Down conditions
Open (Blow off duration)
700 K
Less than 10 sec.
130 bar
Heater-2
Size(mm)
Valve position
Tempreture
Pressure
Valve position
Tempreture(Flow)
Response time
Pressure(MAWP)
HSV3
300
During heating cycle
Closed
Heater side
PRV side
1700 K
Ambient
2 bar
Ambient
During Blow Down
Open
150-300K
Less than 10 sec.
130 bar
HSV4
300
HSV6
300
Operating conditions
During heating cycle
During Blow Down
Closed
Closed
Heater side
Tunnel side
Heater side
Chimney side
1700 K
Ambient
<1700 K
Ambient
2 bar
0.1mbar(Vacuum)
130 bar
Ambient
During Blow Down
During heating cycle
Open
Open
1700 K
1700 K
Less than 3 sec.
Less than 10 sec.
130 bar
2 bar
63
HSV8
200
During heating cycle
Closed
Heater side
Vent side
1700 K
Ambient
2 bar
Ambient
Blow Down conditions
Open (Blow off duration)
1700 K
Less than 10 sec.
130 bar
Size
End connection
Cycle of operation
10,000 cycles
Flow direction
Flow to open
Actuation
ACTUATOR
Safety
Fail to close
Command fluid
Air / Hydraulic
Redundancy
Level three
Pipeline
Pipe size
PRV to heater
12
Heater1 to Settling
12
Approximate Working
Length
chamber
Heater2 to Settling
12
chamber
Working
pressure
Temperature
(m)
(MPa)
(K)
25
13
TBD#
18
13
700
13
1700
Heater to chimney
12
35
0.6
1700
Heater1 to vent
13
TBD
Heater2 to vent
13
TBD
#TBD-To be decided
64
The pipeline connecting heater to settling chamber shall be provided with internal insulation
liner. The purpose of liner is to maintain uniform temperature in the axial and radial
direction. The liner will be perforated for pressure communication and may be required to
be heated to minimize temperature drop in the flow in axial and radial direction. The liner
and piping should have adequate arrangement for thermal expansion compensation. The
pipe connecting PRS to HSV 1 & HSV 3 shall be without any insulation liner. All pipelines
will be designed, fabricated and integrated for the flow parameters as given in Table 3.4.
65
This system include sensors, signal conditioners, cables, cable conduits, patch
panels, instrument racks, intelligent controller with appropriate interface modules, data
display terminals, data storage units, interfacing units etc. One or more intelligent
controllers may be employed for the handling of above mentioned subsystems in closed
loop if required. All necessary interlocks, redundant systems should be built within the
system. This system should be of fault tolerant design in terms of software & hardware. The
controllers should be strategically positioned in order to safe guard the system even in case
of fire.
In addition to above, Instrumentation & control system should be designed for meeting
following functional requirements.
1. Total AHS operation should be fully automatic with manual over ride. In case of any
type of fault, the controller should tolerate and bring the system to the normal state
without seeking for human intervention. All the control loop elements should have
redundancy components.
2. It should have emergency shutdown button for stopping of AHS in case of
emergency.
3. SCADA based GUI environment to be made available for all process parameters. In
case of deviation of any process parameter from its nominal values, the system
66
should pop up the suitable alert signals to the operator in the form of alarms, LED
display etc.
4. Software (test code) to be developed as per IEEE 12207 standard.
5. It should acquire the data of critical parameters at 10samples/sec for round the clock.
6. It should communicate some of the important process parameters (user selected)
using TCP/IP protocol to the main SCADA which will be available at the master
control room.
Instrumentation & control system should have the following features
1. Well proven & Rugged system
2. Testability
3. Availability of components in the future (COTS are preferable)
4. Flexibility in modifying the test code (software) as per requirement
5. Expandable in terms of channel count
6. Provision for debugging the software
7. Suitable to the test environment conditions
8. Password protection for unauthorized access deny
9. EMI/EMC, CE compliances
The contractor should indicate the procedure to be followed in case of emergency and
implement the same with the proper sign boards, precautions, dos & donts etc. The source
code along with the licensed software is to be handed over to department. The contractor
has to provide the training on the application software & test code to the department
personnel. Supplying of suitable capacity UPS is in the contractor scope. An industrial PC
of latest processor with touch screen colour monitor available at the time of installation,
shall be provided.
3.3.16 MEASUREMENTS
Some of the measurements on heater for its thermal control and also for safety
compliances are
1. Bed Temperature Measurement: It is to be performed along the height of the heater.
Suitable thermocouples along with thermo-well (i.e, thermocouple assembly) are to be
provided for measurement of bed temperature. Thermocouple assembly should be
designed such that it will withstand for the operating conditions. RTDs are to be
67
3.3.17.1 DESIGN
I. The design of the system, sub-system and the components shall be done to meet
the specifications and the functional requirements laid out in the document.
II. The design shall be based on the standards/codes mentioned and if an
equivalent/better practices are followed, the same shall be informed in advance to
the department and the approval shall be obtained.
III. The design shall be analyzed for the critical conditions and the soundness shall be
established with adequate factor of safety as per ASME.
IV. Detailed thermo-structural analysis will be carried out.
V. Fatigue Analysis will be carried out
VI. The details of the design and analysis carried out for each shall be documented and
produced whenever required.
VII. The system design and analysis shall be totally reviewed and approved by the
mutually agreed third party Inspection agency (TPIA) like LRIS, BVQI, DNV etc. The
design shall be scrutinized and approved by the Department, before taking up the
realization/procurement.
68
VIII. Material specifications, their form, condition and acceptance criteria shall be brought
out in the design.
IX. Weld joints details, RT & PT acceptance, internal surface finish, details of support
structure, foundation and erection shall be clearly mentioned and presented to the
department with the approval of third party.
X. The flange joints shall be designed for both pressure and vacuum levels mentioned.
Seals shall be designed in such a way that they serve for a period of at least 2 years.
XI. In the case of components that need frequent assembly and dismantling, the
Contractor may propose an alternate joint design for the specified operating
conditions. Contractor can propose an alternate joint for easy assembly/ dismantling
instead of bolted flange joint proposed by the Department.
XII. During the design phase any change in the design input (major/minor) shall be
accepted by the Contractor and incorporated.
XIII. If need arises, the Department may involve and interact during the deliberations
between the Contractor and TPIA.
XIV. However, it is the responsibility of the Contractor to ensure the soundness of the
design to meet the functional requirements of the systems.
XV. Permissible sound level from any system is allowed to be 85 dBA from a distance of
1m.
3.3.17.2 MATERIAL
I. Qualified material shall only be used for fabricating the components
II. Material shall be identified for each component and the traceability shall be made.
III. Each batch of material shall undergo testing in terms of chemical composition,
mechanical properties under the surveilence of mutually agreed TPIA like LRIS,
BVQI, DNV etc..
3.3.17.3 FABRICATION
(i)
Fabrication of the components shall commence only after approval of the design by
the Department
(ii)
Before commencing the fabrication, the Contractor shall prepare the detailed
fabrication process drawings, process plan, quality control plan and get the approval
from the TPIA prior to submission to Department.
(iii) All the welding shall be done by qualified welders only. Welders qualification shall be
done in accordance with ASME section IX, under the surveillance of TPIA
69
(iv) All the weld joints shall be qualified in accordance with ASME code section IX
(v)
(vi) For nozzles which are available on heater shell, reinforcement, stiffener rings will be
as per ASME section VIII- division 2 and shall be attached at the external surface by
fillet welding.
(vii) Suitable process shall be evolved, for relieving the stresses on welded joints; details
shall be furnished regarding the proposed scheme of stress relieving in the process
plan.
(viii) Considering the size of the system, the Contractor shall plan and schedule the
fabrication activities at the erection side also, in the department. The Contractor shall
indicate electrical power requirements for the work, which shall be made available on
chargeable basis.
(ix) The Contractor shall make arrangements for necessary fabrication equipments
including handling for site work at the department premises.
(x)
The Contractor shall agree to accommodate minor changes, if any, during the course
of fabrication.
II.
All the casting shall be subject to sounding test technique for flaw detection.
III.
Critical stages shall be identified, where TPIA shall be involved to carry out
surveillance inspection
IV.
Weld joints of pressure systems in addition to NDT, shall be qualified individually for
leak rate less than 10-8 Pa m3/s of helium.
V.
All the inspection/testing at every stage of fabrication of components/subsystem/systems shall be as per the approved plan, under the surveillance of the third
party inspection agency. All the reports shall be prepared by the manufacturer and
certified by the TPIA.
70
VI.
Acceptance test like hydrostatic/vacuum/leak tests shall be carried out under the
surveillance of TPIA, to the levels specified for each system as per applicable ASME
code. Apart from inspection by the TPI agency, our representative (s) shall also
witness and certify the hydrostatic/vacuum/leak tests and any other test as may be
deemed necessary.
VII.
The right and the authority of the final acceptance of the system shall be based on
the scrutiny of the inspection/ testing records, by the Department.
VIII.
Marking: The pressure vessels shall be stamped with permanent and clearly visible
identification marks at an accessible location. The details such as water capacity,
service pressure, hydraulic test pressure, and material of construction, manufactures
serial number, date of inspection and inspectors stamp shall be marked.
IX.
It shall be the Contractors responsibility to arrange for and co-ordinate with the
TPIA.
3.3.17.5 SPARES
The Contractor will supply all critical spares. A tentative list is given for reference.
1
10 % of installed qty.
Burner
2 no.
2 no.
All O rings
2 sets
All Gaskets
2 sets
10 % of installed qty.
10 % of installed qty.
71
3.3.19 DOCUMENTATION
Three copies of the following documents have to be submitted by the Contractor.
I. Documents along with quotation: A complete technical description of the system
shall be furnished. The following shall be highlighted.
-
Burner specifications
II. Sooner after getting purchase order: The design documents shall be reviewed
and approved by the Third Party Inspection (TPI) agency for compliance with the
requirements of the relevant design codes as specified in the purchase order The
documents duly approved by the TPI agency shall be submitted to the Department
within 2 months from the date of the purchase order. These documents are subject
to corrections by the Department and only upon approval by the Department, the
Contractor will proceed for fabrication. However, our approval shall not absolve the
supplier responsibility/contractual obligation to comply with the specification of the
system. For LPG system the Contractor has to obtain the required certificate from
Chief Controller of Explosives (CCE), Nagpur as per relevant standard.
III. Design documents, analysis reports for air heating system approved by TPIA
IV. Fabrication drawings, process plan and QC plan approved by TPIA
V. Inspection reports at each stage of realization systems and pre-delivery certified by
TPIA
VI. Reports of tests/acceptance carried out for the bought out components
VII. Reports of mandatory functional and acceptance tests
VIII. However, the Departments approval shall not absolve the Contractors responsibility
to comply with the specifications and obligations of the contract.
IX. Consolidated reports, system wise, in a document form shall be submitted to the
Department for approval/acceptance
X. Report of the Functional tests and Acceptance tests of the air heating system in the
integrated condition.
72
3.4 DELIVERABLES
The list of deliverables is given below in Table 3.5.
Table 3.5: List of deliverables
Sr. no.
1
Item
Qty.
2 nos. (1 each)
8 nos.
+ 2 nos (HSV2
piping, etc.
HSV4- 1 each).
73
2 nos.
detector)
4
1 no.
1 no.
1 no.
TBD To be decided
74
1no.
1no.
TBD
1no.
Tunnel System
Hot air
from
heater
Settling
Chamber
Nozzle
Test section
& model
incidence
mechanism
Diffuser
System
Connecting
duct &
After Cooler
Cold air to
vacuum
chamber
75
In hypersonic wind tunnel air needs to be preheated (475 K to 1700K) before it enters the
settling chamber to prevent liquefaction of air in the test section after passing through
nozzle. Therefore, it is necessary to provide insulation liner in the settling chambers and
also flow manipulators have to be designed to withstand high pressure and high
temperature environment.
Nozzles
b.
Cylindrical duct
Flow manipulators
Thermal insulation/liner
Support system
The length of the settling chamber is kept constant from the interfacing point of view. The
settling chamber has been divided into three segments for easy fabrication and
maintenance. Both the settling chambers shall be designed with thermal insulation to
prevent heat loss from the hot air. The schematic of the settling chamber with details of flow
manipulators for settling chamber 1 (SC 1) and settling chamber 2 (SC 2) are shown in
Fig. 4.3 and Fig. 4.4.
2 no.
Outlet diameter**
600 mm (for SC 1)
300 mm (for SC 2)
5965 mm (Approximate)
Overall length
77
Design pressure+
Operating flow temperature
13 Mpa for SC 1
13 MPa for SC 2
Material of construction
Shell
SA 516 Gr. 70
Flow manipulator
Insulation liner
Material of construction
Shell
SA 516 Gr. 70
Flow manipulator
INCONEL 718/Haynes-214
Insulation liner
**The dimensions given here are the required internal diameter of insulation liner.
+Before starting the blow down the settling chamber shall be evacuated to 0.01 mbar hence
design shall be checked for external pressure.
78
THERMAL INSULATION
PP1
Hole dia.
: 30 mm
Pitch
: 34 mm
No. of holes : 253
Porosity
: 63.25%
PP2
Hole dia.
Pitch
No. of holes
Porosity
: 20 mm
: 25 mm
: 451
: 50.11%
PP3
Hole dia.
: 10 mm
Pitch
: 15 mm
No. of holes : 1303
Porosity
: 36.19%
PP4
Hole dia.
Pitch
No. of holes
Porosity
: 5 mm
: 9 mm
: 3619
: 25.13%
EXIT
IN
Fig. 4.3 Schematic of the SC 1 with flow manipulator details
79
THERMAL INSULATION
PP1
Hole dia.
: 30 mm
Pitch
: 33.7 mm
No. of holes : 61
Porosity
: 61%
Hole dia.
Pitch
No. of holes
Porosity
Hole dia.
Pitch
No. of holes
Porosity
PP3
: 10 mm
: 15 mm
: 313
: 34.78%
Hole dia.
Pitch
No. of holes
Porosity
PP2
: 20 mm
: 24 mm
: 121
: 53.78%
PP4
: 5 mm
: 9 mm
: 883
: 24.53%
EXIT
IN
80
4.1.3.3 SHELL
The settling chamber outer shell shall be designed for the internal working pressure of
13 MPa as per the ASME code. The outer shell shall be made out of SA516 grade 70 or its
equivalent material. The Contractor shall carry out the thermal analysis of settling chamber
considering four blowdowns per day, with an interval of 2 hr between two successive
blowdown. Water jacket may be required to be provided on the shell for offline cooling in
order to bring down the shell temperature before next blowdown. Sufficient numbers of
lifting eye bolts shall be provided on each section to facilitate safe handling by overhead
cranes during maintenance.
4.1.3.4 JOINTS
The settling chamber can be divided into three segments. All the three segments of the
settling chamber shall be assembled together by flanged joints using suitable fasteners.
The end flanges shall be designed to interface with 12 pipe line flange in the upstream end
and nozzle flange in the downstream end. The flanges and fasteners are to be designed for
the pressure and temperature mentioned above as per ASME code. The joints should be
leak proof both at high pressure and vacuum and the vacuum leak rate should not exceed
81
10-8Pa m3/s. suitable gaskets, seal shall be provided in the joints to arrest leak both at high
pressure and vacuum at high temperature. All the segments shall be assembled together
within the concentricity of 1 mm and perpendicularity of 1 mm for the total length of 5.9 m.
The Contractor shall work out the limits of concentricity, perpendicularity, positional
tolerance of bolt holes in the segment level to achieve the above specified tolerances in the
assembly and shall incorporate in the fabrication drawings. The Contractor may propose an
alternate joint design in place of bolted flange joint proposed by the Department with the
consideration of easy assembly / dismantling by the operator.
82
4.2 NOZZLES
4.2.1 INTRODUCTION
Nozzles are required to accelerate the flow from low speed to high speed. Convergentdivergent contoured nozzles are proposed. Five set of assemblies are required for
simulation of five different Mach number conditions. The nozzles are assembled with the
settling chamber in the upstream end and with the test section in the downstream end.
Convergent region
Throat region
Cooling system for throat region( For Mach 8,10 & 12 Nozzles only)
Divergent region
Aerodynamic contours of the nozzles shall be given by the department. The overall length
of the nozzle assembly is 7m. Schematic of a typical nozzle assembly and support
structure in the tunnel circuit is shown in Fig. 4.5. Diagram of the nozzle assembly for
individual Mach numbers is shown in Fig. 4.6. Preliminary analysis shows that nozzles for
Mach 8, 10 and 12 need to be cooled at the throat. However, the Contractor will carry out
the detailed heat transfer analysis to ascertain it. The uncooled nozzle throats (Mach 5 &
83
6.5) should be free to expand. A tentative scheme is shown in the sketches. Tentative
scheme is also shown for water cooled nozzles (Mach 8, 10 & 12). However, Contactor
will finalize the schemes based on detailed thermo structural analysis. The Contractor will
also finalize the requirement of off-line cooling considering four tests per day with an
interval of 2 hr between two successive tests.
Test section
Nozzle cooling
Settling chamber
Nozzle
Diffuser
Fig 4.5 Schematic of a typical nozzle assembly and support structure in tunnel circuit
84
1000
500
800
800
1000
1000
1200
700
124
600
3
see detail E
see detail E
see detail E
M5
see detail E
1000 1700
see detail E
30 80
Detail E
500
727
600
800
800
1000
see detail D
1000
see detail D
1200
see detail D
973
see detail D
1000 1700
see detail D
M6.5
30 80
see detail D
650
500
800
800
1000
1000
1200
1050
cooling
circuit
300
3
see detail C
see detail C
see detail C
M8
see detail C
30 80
Detail C
85
1099
1700
500
800
500
800
1000
1000
1200
1200
cooling
circuit
300
3
see detail B
see detail B
see detail B
see detail B
1150 1700
see detail B
M10
80
30
Detail B
750
800
800
1000
1000
1200
1450
Water cooled
throat
2
see detail A
see detail A
see detail A
see detail A
1213 1700
see detail A
M12
80
30
Detail A
Fig. 4.6
4.2.3Technical Specifications
The overall length of the nozzle is 7.0 m and the nominal exit diameter is 1 m. The nozzles
shall be divided into number of segments based on fabrication and inspection feasibility
maximum number of segments is limited to eight numbers. The dimensions and operating
conditions of the nozzles are summarized below in Table 4.1. Butt welded flange with
elastomeric o-ring shall be provided on each segment. There should not be any step inside
profile due to flange joint. Internal contour of the nozzles will be supplied by the department.
Contractor has to carry out detailed mechanical design, thermo-structural analysis and
cooling system design. As tunnel components will be evacuated before the actual
blowdown, the design shall be checked for external pressure.
86
Table 4.1
DIMENSIONS
Mach
Mach
Mach
Mach
Mach
5.0
6.5
8.0
10.0
12.0
Overall Length, m
7.0
Inlet Diameter, m
0.6
0.6
0.3
0.3
0.3
Throat Diameter m
0.190
0.107
0.073
0.043
0.028
Exit Diameter, m
1.000
1.000
1.099
1.150
1.213
Convergent Length, m
1.22
0.98
0.90
0.75
0.50
Divergent Length, m
5.78
6.02
6.10
6.25
6.50
3.0
10
10
10
10
Flow Temperature, K
400
600
800
1100
1400
4.2.3.1 MATERIAL
Table 4.2
Mach
No.
5.0
6.5
8.0
10.0
12.0
AISI
AISI
304L
304L
AISI
304L
AISI
AISI
AISI
AISI
AISI
304L
304L
304L
304L
304L
AISI
AISI
AISI
AISI
AISI
AISI
304L
304L
304L
304L
304L
304L
AISI
AISI
AISI
AISI
AISI
AISI
304L
304L
304L
304L
304L
304L
AISI
AISI
AISI
AISI
AISI
AISI
304L
304L
304L
304L
304L
304L
AISI
AISI
AISI
AISI
AISI
304L
304L
304L
304L
304L
15-5PH*
15-5PH
Berylco *
15-5PH
Berylco *
Berylco *
3
15-5PH*
AISI 304L
4.2.3.2 JOINTS
i.
All the segments of the nozzles shall be assembled together by flanged joints using
suitable fasteners. The end flanges shall be designed to suit with the settling chamber
87
flange in the upstream end and test section in the downstream end. The number of
segments is driven by fabrication and machining feasibility. The Contractor must strive
for minimum number of segments. In case of limitation of in house facility, the
Contractor must make use of facilities available in other places in the country.
However, maximum number of segment permissible is eight. Apart from these joint
there should be a flange on each nozzle assembly as shown in Fig. 4.5 to interface
with test section. It should be designed to withstand nozzle thrust, load due to thermal
expansion.
ii.
The flanges and fasteners shall be designed for the required pressure and
temperature level as per relevant standard (ASME) with adequate factor of safety
The joints shall be leak proof both at high pressure and vacuum (10-2 mbar). Suitable
iii.
gaskets / seals shall be provided in the joints to arrest leak both at high pressure and
vacuum at elevated/room temperature.
iv.
All the segments shall be assembled together within the concentricity of 1mm and
perpendicularity of 1mm for the total length of 7m. The Contractor shall work out the
limits of concentricity, perpendicularity, positional tolerance of bolt holes in the flanges
in the segment level to achieve the above specified tolerance in the assembly and
shall incorporate in the fabrication drawings. Suitable provision for lifting shall be
provided in each segment.
v.
There should not be any step at the joint interface. The Contractor should carry out
suitable interface design to take care of this aspect. Suitable locating pins shall be
provided in flange.
The contour of the inside machined surface of the nozzle shall be within the tolerance
of 0.12 mm and shall be maintained throughout. The X and Y coordinates of the
contour shall be measured at an interval of 100 mm along the axis at 8
circumferential locations. The CMM facility for inspection should be available at
machining centre.
88
Convergent and throat segment of the nozzle shall be hydrostatically tested as per
standard. The complete nozzle assembly shall be tested for vacuum leak test to ensure that
the leak rate should not exceed 10-8 Pa-m3/sec.The end closure shall simulate the mating
flange configuration.
89
4.3
TEST SECTION
4.3.1 INTRODUCTION
The test section is a closed chamber where the test model is placed during the blowdown
and measurements are carried out. The rear end of nozzle is projected into the test section
in the upstream side and the front end of the diffuser known as scoop assembly (flow
collector) is projected into the test section in the downstream side.
Model incidence mechanism is housed in the test section. It is required to inject the model
into the flow and to retrieve it after the measurements are completed. This system will
position and orient the model with respect to the tunnel axis at a desired and pre-planned
location.
90
SCOOP
ASSEMBLY
DOOR
COMPARTMENT-1
SCOOP
SUPERSONIC
DIFFUSER
NOZZLE
PITCH
MECHANISM
AXIAL
MECHANISM
INJECTION
MECHANISM
COMPARTMENT-11
Fig. 4.7
4.3.3.1 COMPARTMENT - I
(Refer Fig 4.7 )
The size of the compartment-I is 6m (L) x 3.5m (W) x 3.0m (H) (internal dimensions). The
nozzle assembly, scoop assembly and supersonic diffuser shall be integrated with the
compartment - I. The details of the interfaces are given below:
nozzle assembly. Test section will be subjected to various loads like nozzle thrust, forces
due to thermal expansion of components between heater and test section, etc. Test section
should be suitably designed to withstand the above loads.
c. DOORS
Two sliding doors shall be provided on both sides of the compartment - I. The door size
should be 2 m (L) x 2 m (H). The doors shall be opened / closed by an automated
mechanism and locked tightly with the test section without any leak by providing necessary
sealing in the closed condition. The doors shall be designed to open by sliding along the
tunnel axis by providing proper guide ways. A suitable mechanism (Hydraulic/ electric) for
opening and closing the doors and for locking the door with the test section shall be
designed by the Contractor.
The Contractor should design for a flange on the sliding doors to mount 700 mm schlieren
window glass. The sliding door mechanism shall be designed in such a way that the
parallelism between the two opposite schlieren windows does not get altered. The center of
schlieren windows shall be at 1.5m from the floor. The two schlieren windows should be
coaxial within 0.5 mm. Glass windows for schlieren to be fixed with metallic frames. The
92
metallic frames are to be integrated with the test section doors on both side and parallelism
of 1 minutes need to be maintained. Dummy metallic windows shall be provided.
4.3.3.2 COMPARTMENT - II
The size of the compartment - II is 4.4m (L) x 3.5m (W) x 6.1m (H). The Model Incidence
Mechanism is rigidly mounted in compartment - II before injection. A door of size 1m (W) x
2.0m (H) shall be provided in the compartment- II for the personnel to enter for
maintenance. A suitable mechanism shall be provided for opening / closing the door and a
locking system to keep the door vacuum tight with the compartment - II. The compartment II of the test section shall be grouted to the ground and should be designed to withstand the
loads like nozzle thrust, thermal expansion forces.
vacuum leak and minimize the signal noise. Additional dummy flanges shall be provided for
meeting futuristic requirements. The exact details such as number of ports and sizes shall
be decided after mutual discussion.
three angular movements for changing the orientation of the model with respect to
the flow axis (Pitch - , Yaw - and Roll - ).
Each of these movements is obtained and controlled by a separate driving mechanism.
Total five driving mechanisms need to be provided. For conventional force and pressure
measurement, model can be injected within 2 sec whereas for heat transfer measurement,
the model needs to be injected at much faster rate (within 200 milliseconds).
Yaw mechanism
Horizontal mechanism
Vertical mechanism
(for injection)
95
b) MIM in Compartment I at = 0
a) MIM in Compartment II
(before injection)
(after injection)
c) MIM in Compartment I at = 45
96
Sl no
Parameter
Specifications
1.
Quantity, Nos.
1
1.75 m approx.
2.
Injection distance
3.
Injection time
4.
Injection drive
Hydraulic/ Electric
5.
Pitch range
-10 to +45
6.
Pitch drive
7.
Pitch rate
8.
Yaw range
-10 to +10
9.
Yaw drive
10.
Yaw rate
11.
Roll range
-90 to +90
12.
Roll drive
Electrohydraulic / Electromechanical
13.
Roll rate
1 /s to 25 /s at variable rate
14.
Axial movement
- 200 to +200 mm
15.
Axial movement
linear actuator
16.
~ 5 mm/s
17.
18.
Accuracy
0.05 or better
The origin of the coordinate system is fixed at the centre of arc of the sector.
Suitable position sensors, limit switches must be provided for all the angular movements
and linear movements. These sensor output shall be used as a feed back for operating the
MIM in closed loop. Triple mode redundancy is to be provided for these sensors. The
contractor shall provide the electrical interfacing details of these sensors to the department.
During the sweep of any one of the angles, variation of other angles should be within
0.05.
97
However, the Contractor is not constrained to provide the above drive system and is
free to design a suitable drive system, which shall meet the requirements.
4.4.3.1
i.
DESIGN INPUT
Model weight and size: The weight of the model including sting is approximately 30 kg.
Slender model of 1m length can be tested. Wing body model of 500 mm wing span
can be tested.
ii.
Aerodynamic design: The model experiences aerodynamic loads and moments during
the blowdown. Maximum aerodynamic forces and moments acting on the model at the
model centre of rotation are given below:
o Normal load
: 6000 N
o Axial load
: 3000 N
o Side force
: 3000 N
o Pitching moment
: 1500 Nm
o Yawing moment
: 350 Nm
o Rolling moment
: 150 Nm
b.
c.
d.
98
4.4.3.2
CONTROL
All the operations will be pre-programmed from the main control console of the tunnel. The
system shall be compatible to accept the commands from the main control console
computer and feed back from the system shall be provided to the main control for display of
, and in the main control console computer. A control panel with manual override
shall be provided near the tunnel test section.
4.4.3.3
The model incidence mechanism shall be integrated with the test section such that the
centre of arc of the sector shall coincide with tunnel centreline ie 1.5m from the floor and
shall be within the limit of 1 mm. The model incidence mechanism shall be rigidly mounted
in the compartment II of test section.
4.5 DIFFUSER
4.5.1 INTRODUCTION
Diffuser of the wind tunnel system is intended to capture all the air from the nozzle flow in
the test section and convert the kinetic energy of the flow into pressure energy i.e. to
decelerate the flow and recover the total pressure. It is connected in the downstream end of
the test section through a flanged joint & upstream end from connecting duct. The
supersonic diffusers shall be mounted on the rails and subsonic diffuser shall be on fixed
support grouted to floor.
4.5.2
SYSTEM CONFIGURATION
Scoop assembly
Subsonic diffuser
Entire diffuser assembly shall be supported on rails. Schematic of the outline of the diffuser
is shown in Fig 4.10.
Scoop
Subsonic diffuser
100
Vacuum isolation
valve
Test section
Sub-sonic diffuser
assembly
Scoop assembly
1000
18,5
12
15
50
Test
Section
Supersonic
Diffuser
scoop
mechanism
02
1
2500
1800
996
1000
970
Bellow
A slot shall be provided on the bottom of the scoop assembly to accommodate the test
model. The size of the slot shall be based on the size of the model incidence
mechanism strut/sector and shall be 1.3m L x 0.5 m W (tentative).
To reduce the flow induced vibration from the scoop exit it should have movable guide
support in the diffuser.
The length of the constant area duct is 9.5 m. The internal diameter of the constant area
duct is equal to the outer diameter with minimum clearance and subsequent to it, the
diameter is 1 m. The constant area duct is water cooled to maintain the shell
temperature at maximum 333 K. The schematic of constant area duct is given in
Fig 4.12.
Overall length
: 9.5 m
Diameter
: 1 m nominal
Design pressure
Flow Temperature
: 1400 K (maximum)
: 333 K
Material of construction
The wall temperature of the diffuser shall be limited to 333K. Suitable cooling system shall
be designed by the Contractor to achieve this temperature limit. Total number of segments
should be limited to three. Individual segment is assembled together with flange joints. An
expansion bellow shall be designed and fabricated for the working conditions as shown in
Fig. 4.12. The joints shall be made leak proof in both high pressure and vacuum (vacuum
leak rate should not exceed 10-8 Pa m3/s) by providing suitable interface and downstream
flange shall be designed to suit with the vacuum isolation valve.
102
103
Nozzle
Cooling
water
in
15
1000
Nozzle
1100
Cooling
water
out
3500
4000
500
1500
9500
Cooling water in
Nozzle
2000
2,5
1000
Cooling
water
out
4000
4000
11450
104
3450
Inlet diameter
: 1m
Outlet diameter
:2m
: 2.50
Overall length
: 11.45 m
Design Pressure
: 0.4 MPa
Flow temperature
: 1400 K
Material of construction
Design
: As per ASME
The wall temperature of the diffuser shall be limited to 333 K. Suitable cooling system shall
be designed by the Contractor to achieve this temperature limit. The Contractor shall
design the diffuser for a design pressure of 0.4 MPa and temperature of 333K as per ASME
code.
temperature).
Similarly
suitable
arrangement
shall
be
provided
for
temperature
measurement. Tentative measurement location is shown in fig 4.12 & fig 4.13. Number of
ports, location, etc will be finalized based on mutual discussion.
: 1 No.
Type
Body material
Sealing material
Make
: VAT / GMBH
106
Aftercooler
Sub-sonic diffuser
assembly
Vacuum isolation
valve
Connecting
duct
Bellow
Scoop assembly
assembly
Water
jacket
Connecting
duct
Aftercooler
Man hole
ground level
: 1 no.
Entry diameter
: 2000 mm
: up to 1400 K
Design code
107
4.7.3.2 JOINTS
The connecting duct can be divided into two segments. The segments will be assembled
together by flanged joints using suitable fasteners. The end flanges shall be designed to
suit the upstream and downstream flange joints. The flanges and fasteners are to be
designed for the pressure and temperature mentioned above as per ASME code. The joints
should be leak proof both at high pressure and vacuum and the vacuum leak rate should
not exceed 10-8 Pa m3/s. Suitable gasket / seal shall be provided in the joints to arrest leak
both at high pressure and vacuum. The Contractor may propose an alternate joint design in
place of bolted flange joint proposed by the department with the consideration of easy
assembly / dismantling by the operator.
4.8 AFTERCOOLER
4.8.1 INTRODUCTION
Aftercooler is a heat exchanger intended to cool hot air coming from diffuser to
temperature less than 333K before it enters the Vacuum spheres. A suitable heat
108
exchanger shall be designed with the constraint of pressure drop not exceeding 10% of the
inlet pressure. The requirement of Aftercooler is on-line cooling of the hot air stream
coming out of the diffuser. A counter flow type heat exchanger (shell-and-tube, STHE) has
to be designed as per Tubular Exchanger Manufacturers Association (TEMA) to meet the
requirement. In this scheme, soft water will be used as coolant flowing inside the shell over
the tubes and hot air, which is the working fluid, flows inside the tubes. Schematic
arrangement is shown in Fig 4.15
Tube &
tube sheet
Shell
The mass flow rate, corresponding temperature and pressure for each operating Mach
number are given in Table 4.4. The Contractor shall choose the most critical condition
from the table and design the Aftercooler. The temperature of air at the outlet of
aftercooler should not exceed 333 K for all operating conditions. Aftercooler should be
designed for 4 bar internal pressure and vacuum of 0.01mbar. The leak rate shall not
exceed 10-8 Pa m3/sec. It can be designed as modular in construction for easy
maintenance. Suitable support structure shall be provided which will be grouted to
109
concrete foundation. The Contractor shall supply the suitable pumps, associated
pipelines, tanks etc. Provision will be made available for measuring pressure &
temperature each at inlet and outlet. Suitable adaptor arrangement will be provided for
pressure measurement for nullifying the temperature effect if required. The inlet of shell
shall be water cooled.
The standards to be followed in designing of the system are given in Table 4.7.
The system should cater to test frequency of four per day at each Mach number with an
interval of two hours between two successive tests.
The system shall be designed as per ASME and adequate redundancy shall be
provided in pumps and other equipment.
Table 4.4
Inlet pressure to
Kg/s
Pa
61.38
346
30858
119.55
364
61716
180
377
94117
6.5
16.57
487
10574
6.5
32.38
510
21148
6.5
47.87
525
31721
6.5
63.17
536
42295
6.5
78.31
545
52869
6.5
93.33
553
63443
6.5
108.25
559
74016
6.5
123.08
565
84590
6.5
137.84
570
95164
6.5
152.40
575
105738
6.54
653
4244
12.80
682
8488
Mach
No.
110
Aftercooler
18.94
700
12732
25.02
714
16976
31.04
725
21220
37.02
734
25463
42.96
742
29707
48.86
749
33951
54.74
755
38195
60.60
760
42439
10
1.96
912
1522
10
3.85
949
3045
10
5.70
972
4567
10
7.54
989
6090
10
9.36
1003
7612
10
11.17
1014
9134
10
12.97
1024
10657
10
14.76
1033
12179
10
16.54
1041
13701
10
18.31
1048
15224
12
0.7
1211
643
12
1.40
1257
1287
12
2.08
1286
1930
12
2.75
1306
2573
12
3.42
1323
3217
12
4.08
1337
3860
12
4.74
1349
4503
12
5.40
1360
5146
12
6.05
1369
5790
12
6.71
1377
6433
111
of
heat
Shell-and-tube
heat
exchanger
exchanger
Shell configuration
Counter flow
Coolant (water)
333K
Placement
Horizontal, fixed
Material
Shell
SA-240M-Gr. 304L
Tube
SA-213M-TP 304L
Tube sheet
SA-240M-Gr. 304L
Baffle
SA-240M-Gr. 304L
Shell
SA-240M-Gr. 304L
Standard/code
After cooler
Piping
ANSI B 31.3/31.1
SS pipes
ANSI B 36.19
CS pipes
ANSI B 36.10
ANSI B 16.9
ANSI B 16.11
Flanges
ANSI B 16.5
Gaskets
Pressure gauges
BS 1780/IS 3624
ASTM A 530
112
NDT
ASME Section V
Welding
Radiography
ASTM E 94
The broad scope of inspection shall be as follows. However, the detailed scope of
inspection shall be given in the quotation.
a.
b.
Identification of different component of the system with test and calibration certificates.
c.
d.
Review of X-ray films of radio-graphic tests for possible defects in the weld joints.
e.
Inspection at any stage of fabrication to ensure that the methodology employed for
fabrication is in compliance with the requirements of standards/ codes, practices,
contract specification and the approved documents.
f.
Witnessing of pressure test, leak test and cleanliness test of the system during
fabrication and erection at site.
4.8.3.1
Material Certificates: The material Certificates, detailing the physical and chemical
properties, of the principal pressure-bearing parts shall be provided.
Hardness test
Dimensional check
Functional test: The Aftercooler with all accessories mounted shall be subjected to
functional test to validate the performance for all operating condition.
Dye penetrated test and radiographic test with x-rays or gamma rays to 2-T sensitivity
of all butt welded joints.
Material certificate: The material certificates, detailing the physical and chemical
properties, of the principal pressure-bearing parts shall be provided.
Welding joints test: Any butt welding joints in the valve shall be subjected to radio
graphic test with X-rays or gamma rays to 2-T sensitivity.
Soundness test for casting: all the casting shall be subject to soundness test with radiographic or ultra-sonic technique for flaw detection.
Hydraulic shell pressure test: The valve, prior to assembly with the bellows, in partially
open position, shall be subject to pressure test with water ( with suitable corrosion
inhibitor) at the maximum rated working pressure of the particular pressure rating class
of the valve as per standard. The test procedure and acceptance criteria shall be as per
BS 6755 Part 1 or API 598 or ANSI B 16.34.
Pneumatic seat test (for ball valve only): The leak rate across the seat of ball valves
shall be tested with dry air at 0.4 to 0.7 MP by water displacement (bubble) method. The
acceptance criteria shall be as per Rate A BS 67755 Part 1) Or API 598.
Functional test: The valve with all accessories mounted shall be subjected to functional
test to validate the performance.
Marking: All the valves are assigned tag numbers for the sake of identification. The tag
number for each valve, as indicated above, besides size, pressure rating class, material
of construction etc, shall be indelibly engraved on the body of the valves.
4.8.3.2.2 PIPES
Visual examination: All the pipes shall be visually examined for workmen-like finish.
114
Dimensional check: One specimen from each lot shall be subjected to dimensional
check.
Chemical analysis: One specimen from each lot shall be subjected to detailed
chemical analysis as per ASTM A 751.
Mechanical Tests: One specimen from each lot shall be subjected to test for
mechanical properties as per ASTM A 370 (including impact test)
Hydraulic pressure test: All pipes shall be hydraulically pressure-tested with Water as
per ASTM A 530.
Ultra-sonic test: All the SS pipes of size DN 25 shall be subject to Ultra-sonic test
(100 %) by contact method as per ASTM A 450.
Eddy current test: all the SS pipes of size DN15 shall be subjected to Eddy current
test as per ASTM E 426.
Flattening test: Pieces of pipes of length 63.5 mm (2.5) cut from the ends of 5 % of
pipe lengths per lot shall be subjected to flattening test as per ASTM A 530 to prove
ductility and soundness.
Inter-granular corrosion test (for SS pipe only): One specimen per lot shall be subject
to inter-granular corrosion test as per ASTM A 262 (practice A/E).
The design of the system, sub-system and the components shall be done to meet
the specifications and the functional requirements laid out in the document.
II.
III.
The design shall be analyzed for the critical conditions and the soundness shall be
established with adequate factor of safety. The design shall be analyzed for thermal
loads, flow induced vibration for all conditions etc.
IV.
The detailed design and analysis shall be documented and produced whenever
required.
V.
The system design and analysis shall be totally reviewed and approved by the
mutually agreed third party agency (TPIA) like BVQI, LRIS etc. The same shall be
115
scrutinized
and
approved
by
the
Department,
before
taking
up
the
realization/procurement.
VI.
Material specifications, their form, condition and acceptance criteria shall be brought
out in the design.
VII.
Weld joints details, RT & PT acceptance, internal surface finish, details of support
structure, foundation and erection shall be clearly mentioned and presented to the
department with the approval of third party.
VIII.
The flange joints shall be designed for both pressure and vacuum levels mentioned.
Seals shall be designed in such a way that they serve for a period of at least 2
years.
IX.
In the case of components that need frequent assembly and dismantling, the
Contractor may propose an alternate joint design for the specified operating
conditions. Contractor can propose an alternate joint for easy assembly/ dismantling
instead of bolted flange joint proposed by the Department.
X.
During the design phase any change in the design input (major/minor) shall be
accepted by the Contractor and incorporated.
XI.
If need arises, the Department may involve and interact during the deliberations
between the Contractor and TPA.
XII.
4.9.2 MATERIAL
I. Qualified material shall only be used for fabricating the components
II. Material shall be identified for each component and the traceability shall be ensured
through a suitable logging system
III. Each batch of material shall undergo testing in terms of chemical composition,
mechanical properties under the surveillance of mutually agreed third party inspection
agency (TPIA) like LRIS, BVQI or any other government approved agencies.
4.9.3 FABRICATION
I. Fabrication of the components shall commence only after approval of the design by the
Department
II. Before commencing the fabrication, the Contractor shall prepare the detailed fabrication
process drawings, process plan, quality control plan and get the approval from the TPIA
prior to submission to Department.
116
III. All the welding shall be done by qualified welders only. Welders qualification shall be
done in accordance with ASME section IX, under the surveillance of TPIA
IV. All the weld joints shall be qualified in accordance with ASME code section IX
V. Fabrication of systems subjected to pressure and vacuum, shall be carried out in
accordance with ASME code section VIII and NDT inspection acceptance shall be as
per ASME code VIII- Division 1 & 2
VI. For nozzles reinforcement, stiffener rings will be as per ASME section VIII- division 2
and shall be attached at the external surface by fillet welding. This enables nozzle to
maintain contour under critical loading and handling.
VII. Inside surface of settling chamber, nozzle, diffuser, etc shall be smooth and polished to
the specified finish levels; No projection in the weld is permitted.
VIII. Suitable process shall be evolved, for relieving the stresses on welded joints; details
shall be furnished regarding the proposed scheme of stress relieving in the process
plan.
IX. Considering the size of the system, the Contractor shall plan and schedule the
fabrication activities at the erection side also, in the department. The Contractor shall
indicate electrical power requirements for the work, which shall be made available on
chargeable basis.
X. The Contractor shall make arrangements for necessary fabrication equipments
including handling for site work at the department premises.
XI. The Contractor shall agree to accommodate minor changes, if any, during the course of
fabrication.
117
IV. All
the
inspection/testing
at
every
stage
of
fabrication
of
components/sub-
system/systems shall be as per the approved plan, under the surveillance of the third
party inspection agency. All the reports shall be prepared by the manufacturer and
certified by the TPIA.
V. Acceptance test like hydrostatic/vacuum/leak tests shall be carried out under the
surveillance of TPIA, to the levels specified for each system
VI. The right and the authority of the final acceptance of the system shall be based on the
scrutiny of the inspection/ testing records, by the Department.
VII. It shall be the Contractors responsibility to arrange for and co-ordinate with the TPIA
4.9.5
DOCUMENTATION
118
VI. The undertaken contract will be declared completed, only on satisfactory performance
of the functional test meeting all the specifications. The responsibility completing the
total contract is with the Contractor.
4.10 DELIVERABLES
The list of deliverables is given in the table below:
Sr.
Item
no.
Qty.
2 nos.
associated piping.
2.
5 nos.
1 no
1 no
5.
1 no+1 no.
of
expansion
bellow
1 no+1 no.
6.
7.
1 no.
8.
1 no.
119
Instrumentation system plays a vital role in the hypersonic wind tunnel. Instrumentation
system is responsible for a) precise & reliable operation of the tunnel as per the time bound
(i.e., event bound) pre-defined sequence during blow down b) performing measurements on
the test article and also on the facility and c) centralized monitoring of health of the
subsystems from the tunnel main control room.
valve (PRV) is an EH actuated control valve whose stem position is to be controlled during
the blow down in order to maintain steady pressure in the settling chamber. Third valve is
manual operated ON/OFF type for maintenance purpose. AHS is used for online heating of
air before passing into the settling chamber. It consists of two cored brick heaters.
Depending on the temperature requirement, only one heater is used for blow down. Each
heater is having 4 Hot shut off valves (HSVs). All the HSVs are EP (or EH) actuated
ON/OFF type. HSV1 & HSV3 isolates the heater from upstream side of tunnel circuit. HSV2
& HSV4 isolates the heater from downstream side of tunnel circuit. HSV5 to HSV 8 are
connected to the open atmosphere through the chimney.
Tunnel system consists of setting chamber (SC), nozzle, test section (TS), model incidence
mechanism, diffuser, vacuum isolation valve and after cooler. SC is of larger cross sectional
area which reduces incoming flow turbulence & flow velocity. Nozzle is used for
accelerating the flow from low speed to high speed. TS is the location where scale down
model under test will be placed. Test article (model) is instrumented with various types of
sensors depending on the requirement. Measurements are performed on the model, which
is the primary aim of hypersonic wind tunnel testing. MIM is positioned inside the test
section and is used for varying model orientation (,,) during the blow down. Diffuser and
after cooler are used for reducing the flow velocity & temperature respectively before
dumping into the vacuum tanks. VIV is the most critical item from the safety point of view.
This valve has to be necessarily open during blow down. This is the first valve to be opened
for a test and the last one to be closed after the test is over.
Vacuum system is used for creating necessary vacuum level in the vacuum tanks (i.e.,
Horton spheres) and also in the test section required for the tunnel operation. Cooling
system is used for providing the water at pre-defined flow rate to all sections where cooling
is required.
121
the blow down. Simultaneously model mounting, flow visualization checks are carried out.
After performing pre-test checks, blow down starts.
Blow down is carried out by tunnel control system. Valve VIV is opened. Valve HSV1 or
HSV3 is opened depending on the heater selected. A suitable parallel circuit in the PRS is
selected depending on the mass flow requirement and valves in this parallel circuit
EGV5/6/7 & MBV1/2/3 are opened. Now EGV4 is opened to admit HP air. PRV control loop
gradually opens the PRV1/2/3 by simultaneously monitoring the feedback signal of heater
pressure which is at the upstream of HSV2/4. When the pressure in the heater attains
desired value, HSV2/4 is opened. PRV control loop maintains desired pressure in the
settling chamber with in the prescribed limits for the desired test duration by taking the
feedback signal from SC. On attaining the desired test conditions in the test section, control
loop of MIM system injects the model into the test section and then perform the sweep
operation as per the time bound pre-defined sequence. Measurements are done for the
desired test duration, typically 20 seconds for force measurements and 2 seconds for
unsteady measurements. After the desired test duration, MIM control loop retract the model
to the tunneloff axis and then PRV control loop closes the PRV. After the test EGV4 is
closed first, followed by EGV5/6/7, HSV1/3, HSV 2/4 and then after a suitable delay VIV is
closed after ensuring that EGV4, EGV5/6/7, HSV1/3, HSV 2/4 are completely closed.
Sequence of operation of the tunnel is given in detail in Annexure.
as
automated
check
out
system
for
functional
checking
of
124
The contractor has to perform the Hardware-in-loop simulation and also demonstrate the
performance of the controller at various input conditions during wind off condition and
during wind on condition with and without integration to the tunnel master control system.
sampling rate. Data acquisition parameters like sampling rate, analog input ranges, analog
input type (differential or single ended), acquisition duration etc.. should be programmable.
Similarly the signal conditioning parameters like bandwidth, gain etc.. should be
programmable. All the acquisition parameters should have time synchronization. Data is to
be acquired very precisely (say chain accuracy <0.5% of applied value). During the test,
few parameters (i.e., user selectable) data is to be displayed in real time in the user
selectable formats like graphical, numerical, digital etc... After the test, the system should
perform the signal processing, data analysis, report generation.
The desired features of this system are same as that of control system as given in section
5.3.1. In addition to these, the system should be reconfigurable as per test requirement.
The contractor has to work out the scheme of measurement system for meeting functional
requirement and supply the same. The proposed system should have above desired
features. Distributed data acquisition system approach is preferable.
main control room. It is to be configured such that it provides the quick grasping to the
operator about the subsystem status by graphical display, numerical display, LED display
etc... This system should receipt the signals in respect of High Pressure System, Air
Heating System, and Vacuum System using TCP/IP protocol which will be available at the
respective subsystem controller. This system should also receipt the critical signals (i.e.,
digital & analog) of tunnel subsystems. This system should acquire the data of critical
parameters at low sampling rate (say 10samples/sec).
The parameters in respect of LPG storage & handling system need to be monitored round
the clock. This system should communicate the information with the suitable alters to the
authorized representative when LPG storage & handling parameters are out of safe
bounds. Arrangement of display units should be of ergonomic design.
The desired features of this system are same as that of control system as given in section
5.3.1. The additional features are
a) Flexibility in modifying the subsystem mimics & display parameters as per requirement
b) Data trending, analysis, notifying maintenance alerts & report generation.
The contractor has to work out the scheme of health monitoring system for meeting
functional requirement and supply the same. The proposed system should have above
desired features.
fault, the control system automatically detects & then abort the tunnel starting (or running)
sequence in use and execute the shut down sequence. In addition to this, the control room
is equipped with push button type emergency shut down control button for stopping of the
tunnel as per pre-defined sequence.
Typical block diagram of fault torrent control loop is shown in Fig 5.4. In which sensor,
signal conditioners are connected in triple mode redundancy. Where as processor & ups
are connected in double mode redundancy. Processor (i.e., embedded controller) is
configured as a hot redundant system. Embedded controller transmits the digitized data in
real time to the host PC.
Sensor, signal conditioner and embedded controller are inter-connected by shielded twisted
pair (STP) instrumentation cable. Embedded controller consists of input / output modules,
ADC, DAC, deterministic processor, application software, RTOS, display unit etc.. The
processor receives the conditioned signal of sensor through the Input modules, digitizes the
sensor signal & perform the computations on feed back signals as per algorithm and
provides the control signal to the servo valve (or solenoid valve) through the output
modules. Servo valve and solenoid valve is used for operating of control valve and ON/OFF
type valve actuators respectively.
127
Model measurements consist of steady pressure, force & moments, unsteady pressure,
and temperature. Steady pressure measurement is performed using either independent
transducers or ESP pressure scanners. Electronic pressure scanning system is detailed for
the acquisition of ESP pressure scanner data. Unsteady pressure measurement is
performed
with
high
speed
DAS
as
sampling
rate
requirement
is
DIG IN - 12
Two pressure transducers (PT) & one resistance temperature detector (RTD) is mounted at
the summing junction of all modules (just before EGV4) which are taken as reference for
the tunnel operation.
Sensors Required
1) PT
QTY: 2 Nos
2) RTD QTY: 1 No
Signals terminated at MCS: ANALOG IN 3
129
ANALOG IN 2
ii) One dedicated low pressure cylinder is planned for the supply of air to the pneumatically
operated valves. Two pressure transducers are mounted on this cylinder. Cylinder is having
one ON/OFF type valve at discharge end. This valve is operated by High pressure control
system. In other words, this valve operation is not under instrumentation system contract
scope. However this valve opening status is to be known to MCS before starting the blow
down.
Requirement: DIN 2 for status monitoring
Sensor Required
1) PT
During the blow down, compressor will be in OFF position. Compressor running status and
readiness of HP system for the blow down is communicated to the MCS.
Signals terminated at MCS: DIG IN- 4
B. PRV 1/2/3 : This valve is an analog control valve whose stem position is varied during
blow down in order to maintain steady pressure in the settling chamber, this valve is
operated by the PRCS. Detailed design & realization of PRCS is under instrumentation
system contract scope. This valve is very critical & has to be controlled as per the predefined instructions. Hence TMR is planned for controlling of this valve. Sensors for
measuring stem position will be supplied by the respective valve supplier.
Requirement:
C. MBV 1/2/3: This is manual operated valve, whose opening/closing status to be known to
MCS before proceeding for the blow down.
Requirement:
DIG IN - 36
DIG OUT - 9
Pipe line (between PRS & HPS) is having pressure relief valve & burst disc. The status of
these equipments is to be monitored during blow down. Two pressure transducers are
mounted on the pipe line at the up stream of PRV which are taken as reference for the
tunnel control.
Sensors Required: PT
QTY: 2Nos
B. Heater vessel
For the tunnel operation, two temperature measurements and two pressure transducers are
planned at the exit of each heater. Thermocouples along with thermo-well are used.
Sensor Required
1) PT
QTY: 4 Nos
DIG IN - 32
DIG IN - 4
133
B. Vacuum spheres
Three vacuum spheres are planned. Each sphere is having two vacuum gauges and
one temperature sensor. These sensors will be supplied by the respective system supllier.
Requirement:
DIG IN - 6 No for status (4 Nos for redundancy scheme)
DIG OUT - 3No for control (2 Nos for redundancy)
Signals terminated at MCS: DIG IN - 6
DIG OUT - 3
This valve should be in closed position when there is no blow down. This valve status is to
be monitored by health monitoring system.
Signals terminated at HMS:
DIG IN - 3
D. Other Valves
VPV valve is located between vacuum pumping system & test section. This valve will be
operated by the vacuum control system. In other words, this valve operation is not under
instrumentation system contract scope. However this valve position is to be monitored
during the blow down.
Requirement: DIN 3 for status (2 Nos for redundancy)
Signals terminated at MCS: DIN 3
134
For the tunnel operation, two pressure measurements & two temperature measurements
are planned on each SC. TMR is planned for pressure measurements.
Sensors Required:
1) Pressure Transducer - QTY: 12 No
2) Thermocouple assembly - QTY: 4 No
Signals terminated at MCS:
ANALOG IN - 16ch
ANALOG IN - 16ch
ANALOG IN - 6ch
DIG IN - 5ch
5.5.1.5.3 MODEL INCIDENCE MECHANISM (MIM): One dedicated control system (i.e,
Model incidence control system) is provided exclusively for the operation of MIM as per the
time bound pre-defined sequence. Detailed design & realization of MICS is under
instrumentation system contract scope. The MIM operation is critical and has to perform the
operation as per pre-defined sequence. Hence TMR is planned for this system.
135
Sensors required for the MIM operation will be supplied by the MIM system supplier.
i) Model Injection & Withdrawal operation: Tentative channel count for this operation is
given below. (assumption: Single point electro hydraulic actuation & position measurement at
one location using three sensors)
Position Control 3 Analog OUT (2Nos for redundancy)
Position Feedback / angular feedback 3 ANALOG IN (2Nos for redundancy)
Extreme Position indication 24 DIN
ii) Model incidence operation: Either electro-hydraulic (EH) or electro-mechanical (EM)
actuator is used for providing the driving force. Tentative channel count for this operation is
given below. (assumption: 3 numbers of EH actuators for three degrees of freedom)
Position Feedback / angular feedback 6 encoder signals & 3 potentiometer signals
Actuator input 9 Analog OUT
Extreme Position indication 20 DIN
QTY: 10 Nos
QTY: 2 Nos
- QTY: 2 Nos
- QTY: 2 Nos
RS-485
- 8ch
Ethernet
- 8ch
transducers are used. These sensors provide analog interface of the order of few milli Volts.
Measurement system is to be configured for 24 channels of unsteady pressure data.
137
- 1 No each
- 1No
Sensors Required
1) PT- QTY: 30 Nos
2) Thermocouple assembly - QTY: 15 Nos
Signals terminated at HMS: ANALOG IN 45ch
Nozzle cooling circuit outlet temperature is one of the important parameter. Hence it is to be
kept as interlock in the control loop.
Signals terminated at MCS: ANALOG IN - 1ch
138
5.5.1.8 MISCELLANEOUS
A. MCS has to trigger the measurement system to start acquisition of model parameters
data. In addition to this, it has to perform handshaking with the measurement system
during blow down. Hence 10(tentative) digital input & 10(tentative) digital output
channels are reserved at both ends for this purpose.
Signals terminated at MCS: DIG IN - 10ch
DIG OUT - 10ch
Signals terminated at MS:
DIG IN - 10ch
DIG OUT - 10ch
B. MCS has to perform handshaking with the MIM controller during blow down. Hence
5(tentative) digital input & 5(tentative) digital output channels are reserved at both ends
for this purpose.
Signals terminated at MCS:
DIG IN - 5ch
DIG OUT - 5ch
DIG IN - 5ch
DIG OUT - 5ch
C. Hydraulic line pressure is to be measured during blow down. Over head tank water
level, water temperature is to be measured.
Sensors Required:
139
5.5.2.1 CONSTANT VOLTAGE SOURCE: These are required for providing excitation to
the potentiometers, limit switches, solenoid valves etc.. Depending on the Voltage and
wattage requirement & placement of the sensors, multiple voltage sources are to be
provided at suitable locations. Voltage sources should be of programmable and capable of
driving solenoid valves.
5.5.2.2 SIGNAL CONDITIONERS: These are required for conditioning of measurement
signals and control loop feed back signals. Measurement signals are originated from
independent pressure transducers, strain gauge balances, thermocouples, RTD etc... The
specifications of signal conditioners are given in Table 5.8. Two stages amplification is
needed if the 5000 gain is not possible.
Signal conditioners required for the control loop feedback signals are to be configured in the
fault tolerant mode.
Preferred Makes: Pacific Instruments, Endevco, Preston, Dewetron, Precision Filter
5.5.2.3 ADC & DAC: ADCs are required for digitization of control system feedback
signals & measurement signals.
ADC specifications:
Input coupling DC
Absolute accuracy ( including Residual gain error, Gain tempco, Ref Tempco,
Residual offset error, offset tempco, INL error, Randaom noise) - less than 0.04%
DACs are required for supply of control signals to the servo valves & solenoid valves. DAC
resolution is 16bit. DAC voltage & current specifications shall be capable of driving
solenoid/servo valves.
5.5.2.4 INPUT/OUTPUT MODULES: The modules at which incoming (or outgoing) cables
will be terminated. This module provides the appropriate interface to (or from) the
embedded controller.
5.5.2.5 CABLES:
Low noise, twisted pair, individually shielded instrumentation cables are required from
measurand to the digitizer end.
For the model measurements, vacuum rated instrumentation cable is required since the
model is positioned inside the test section & in which low pressure of the order of 0.1millibar
is present. One end of the vacuum cable is terminated at the sensor & other end at the feed
through connector on the flange (i.e, vacuum side). The flange is positioned on the test
section body. From the other side of the flange (i.e., air side) STP cable is laid up to the
signal conditioner.
From the digitizer end to control room, either Ethernet or Fiber optic cable is required based
on the mode of signal transmission. Cable exposed to the atmosphere shall be protected in
suitable conduit.
The approximate distances (in meters) of various subsystems from tunnel control room is
shown in Fig 5.8. Each block is 15m (length) X 15m (height).
The flange with 300channel capacity feed through connectors (assorted) is to be supplied
by the contractor. The connector details will be given at later stage.
5.5.2.6 DETERMINISTIC PROCESSORS: These are required for execution of control
algorithms & test code (i.e., software) in real time. These units are to be configured in the
fault tolerant mode.
5.5.2.7
HOST PCs: These are required for real time display of selected parameters
during test. These are also used for channel configuration, test code development &
deployment, feeding of DAQ parameters, health monitoring etc.. before the test.
5.5.2.8
DATA PROCESSING & STORAGE UNITS: These are required for the post test
data analysis, report generation and data storage. Data server should be of large capacity
141
which should automatically transfer the data from HOST PC and store it with proper
tagging.
5.5.2.9
DATA DISPLAY TERMINALS: These are required for displaying test data during
5.6 SOFTWARE
Over all tunnel operation & control, data acquisition system, health monitoring display units,
data servers etc are to be handled by the software. User decided subroutines must be
part of the program. Fault detection and test abort should be one of the parts of the
142
software.
vendors scope. Software coding is to be done as per IEEE 12207 standard compliances.
Tentative tunnel operating sequence is given in annexure. This can be used as a reference
for coding of the software. Detailed failure mode analysis is to be carried out by the
contractor. The source code is to be handed over to department & proper training regarding
the entire operation of the application software and coding of the software to be provided to
the department personnel.
Plat form: LabVIEW, LabVIEW RT.
143
provide the details regarding requirement of number of earth pits, location etc.. to the
department.
5.10 DOCUMENTATION
The contractor should provide all relevant documents like detail design document,
engineering document, requirement fit analysis document, ATP document, system user
manual, trouble shooting manual etc... in the form of soft copy and hard copy in English
language at appropriate time while execution of the contract.
5.11.1
5.11.2
MEASUREMENT SYSTEM
5.12 DELIVERABLES
The list of the deliverables is given in Table 5.9.
145
(PV)
PV
PV
Fig. 5.2: Block diagram of control loop pertaining to the PRS system
146
Fig. 5.7:
147
Fig. 5.8:
Approx. Distances (in meters) of various subsystems from tunnel control room
(Each block is 15m Length X 15m Height)
148
Table 5.2:
149
Table 5.6: Sensors required for facility measurements to be supplied by the contractor
Sl.
Type of
Type
Sensing
No
Measurement
of
element
Range
Accuracy
B.W.
Subjected
Monitor (M)/
(%F.S.)
(Hz)
conditions
Control ( C)/
Temp (K)/
sensor
Interface
Medium
Qty
Location
Pressure (Mpa) /
Shock (g)/
flow rate (kg/sec)
1
PM
PT
SG/
33Mpa
0.1
10
233 323 K
M&C
Analog
Air
HP Manifold
233 to
0.5
10
33Mpa
M&C
Analog
Air
HP Manifold
0.1
10
313K
Analog
Air
Low pressure
SOS
2
TM
RTD
--
323 K
3
PM
PT
SG/
1Mpa
SOS
4
PM
PT
SG/
cylinder
33Mpa
0.1
1000
313K
C&A
Analog
Air
SOS
5
PM
PT
SG/
Upstream of
PRV
12Mpa
0.1
1000
350K*
C&A
Analog
Air
Heater-1
12Mpa
0.1
1000
350K*
C&A
Analog
Air
Heater-2
750K
0.5
10
12Mpa
C&A
Analog
Air
Heater-1
C&A
Analog
Air
Heater-2
C&A
Analog
Air
Settling
SOS
6
PM
PT
SG/
SOS
TM
TC
Type-
180kg/sec
8
TM
TC
Type-
1700K
0.5
10
12Mpa
60.6kg/sec
PM
PT
SG/
12Mpa
0.04
1000
350K*
SOS
10
PM
PT
SG/
chamber - 1
12Mpa
0.04
1000
350K*
C&A
SOS
Analog
Air
Settling
chamber - 2
150
Remarks
Sl.
Type of
Type
Sensing
No
Measurement
of
element
Range
Accuracy
B.W.
Subjected
Monitor (M)/
(%F.S.)
(Hz)
conditions
Control ( C)/
Temp (K)/
sensor
Interface
Medium
Qty
Location
Analog
Air
Settling
Pressure (Mpa) /
Shock (g)/
flow rate (kg/sec)
11
TM
TC
Type-
750K
0.5
10
12Mpa
C&A
180kg/sec
12
TM
TC
Type-
1450K
0.5
10
chamber -1
12Mpa
C&A
Analog
Air
60.6kg/sec
13
PM
PT
SG/
Settling
chamber - 2
0.04
1000
350K*
C&A
Analog
Air
Exit of nozzle
0.04
1000
350K*
C&A
Analog
Air
Plenum chamber
100KPa
0.1
10
350K
Analog
Air
Test Section
0.1
10
350K
Analog
Air
Test Section
SOS
14
PM
PT
SG/
SOS
15
PM
VG
CT
-100Pa
16
PM
VG
CT
100Pa1Pa
17
TM
TC/
Type-
0.5
10
C&A
Analog
Air
Test Section
SG/
0.4Mpa
0.1
1000
350K*
C&A
Analog
Air
10
diffuser
RTD
18
PM
PT
SOS
19
TM
TC
Type-
1400K
0.5
10
0.4Mpa
C&A
Analog
Air
diffuser
20
PM
PT
SG/
0.4Mpa
0.1
1000
350K*
C&A
Analog
Air
350K
0.5
10
0.4Mpa
C&A
Analog
Air
After cooler
SOS
21
TM
RTD
--
outlet
151
Remarks
Sl.
Type of
Type
Sensing
No
Measurement
of
element
Range
Accuracy
B.W
Subjected
Monitor (M)/
(%F.S.)
(Hz)
conditions
Control ( C)/
Temp (K)/
sensor
Interface
Medium
Qty
Location
Cooling water
circuit inlet &
outlet (Nozzle)
Cooling water
circuit inlet &
outlet
(HSVs, pipe
line, SC, MIM,
diffuser, CD )
Cooling water
circuit outlet
(Nozzle)
Cooling water
circuit outlet
(HSVs, pipe
line, SC, MIM,
diffuser, CD )
Hydraulic line
Remarks
Pressure (Mpa) /
Shock (g)/
flow rate (kg/sec)
22
PM
PT
SG/
2 Mpa
0.5
10
350K
M&C
Analog
water
0.4Mpa
0.5
10
350K
Analog
water
28
M&C
Analog
water
SOS
23
PM
PT
SG/
SOS
24
TM
RTD
--
350K
0.5
10
2 MPa
25
TM
RTD
--
350K
0.5
10
0.4 MPa
Analog
water
14
26
PM
PT
SG/
10MPa
0.1
10
350K
Analog
Oil
SOS
27
PM
PT
SG/
pressure ( PRV)
X
0.1
10
350K
Analog
Oil
Hydraulic line
SOS
pressure
(HSV, MIM)
28
Water Level
29
TM
0.5
10
RTD
--
350K
0.5
10
350K
X
water
Note: X - to be decided.
* - Suitable adaptor is to be designed by the contractor for reducing the temperature effect from stagnation temperature to ambient
temperature. If not, sensor capable of withstanding stagnation temperature are to be selected.
152
Analog input
Analog output
Digital input
Digital output
B)
C)
D)
E)
F)
G)
H)
(24dB/octave) or better
Filter Bandwidth
Model Measurements:
Steady pressure using Independent pressure transducer- 1 KHz
Steady pressure using ESP scanner Not Applicable
Unsteady pressure using Dynamic pressure transducer- 100 KHz
Steady forces & moments using strain gauge balance- 30 KHz
Temperature using RTD, Thermocouple, Heat flux gauges-30KHz
Facility Measurements:
Steady pressure using Individual pressure transducer- 1 KHz
Temperature using RTD, Thermocouple -1 KHz
Item
Qty.
1 set
1 set
1 set
154
1 set
10 Nos.
107
Signal Conditioners
As per
configuration*
1 set
As per
configuration*
10
As per
configuration*
11
As per
configuration*
12
Software (Licensed)
1 set
13
UPS
14
15
Surveillance camera
155
Annexure
157
158
Installation tests
This refers to satisfactory installation of equipments at the Hypersonic Wind Tunnel
Project site, to the satisfaction of DRDL.
Commissioning tests
This refers to the demonstration of actual performance of individual systems and
subsystems at the tunnel site, after successful completion of installation.
Note: The entire tunnel will be deemed to be commissioned when four successful
tests out of five are conducted for each Mach number at the maximum pressure and
temperature condition for a steady duration of minimum 20 seconds. All the
consumables during Installation, Commissioning and Testing should be provided by
the vendor.
159