LIQUID PROPULSION SYSTEMS CENTRE, BANGALORE

SEPTEMBER 2017

PROPOSAL FOR WELDING

OF PROPULSION SYSTEM MODULES

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CONTENTS

S no. Particulars Page no.

1.0 Preamble 2

2.0 Scope of work 3

3.0 Contract execution and responsibilities 8

4.0 Process flow chart for realization of Propulsion system modules

10

5.0 Facility requirement 11

6.0 Total work load and period of contract 14

7.0 Quotation 15

8.0 Payment terms 15

9.0 Warranty 15

10.0 General guidelines 16

11.0 Confidentiality Agreement 17

12.0 Fall clause 17

13.0 Security deposit 18

14.0 Summary 18

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1.0 PREAMBLE :

LPSCB is responsible for realization of propulsion system for IRS and GEOSAT

spacecraft. The Propulsion system of GEOSAT class satellite comprises of 5

modules. With the increase in demand for realization of propulsion system for

spacecraft LPSCB proposes to execute realization of propulsion system modules

by external party at LPSCB. The modules details are given below:

� Module-A: It comprises of four flight components. This module has 17 high pressure welds.

� Module-B: It comprises of four flight components. This module has 6 high pressure welds.

� Module-C: It comprises of seven flight components. This module has 16 low pressure welds.

� Module-D: It comprises of five flight components. This module has 16 low

pressure welds.

� Module-E: It comprises of five flight components. This module has 17 low pressure welds.

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2.0 SCOPE OF WORK: The contract envisages realization of propulsion system modules for 10 spacecraft within the time frame of 1 year at LPSCB by External party. The list of activities as tabulated below will be executed by external party for realization of each propulsion system modules: 2.1 Module-A: Activity description Quantity Remarks

Total number of plumb lines 7 Refer figure-1.

Total number of bends for plumblines 2 Total number of tee joints 6 Total number of component assembly 4 Total number of welds including tube preparation. 17 Component welding will be carried out after DP, x r ay completion & clearance by LPSC team for the plumb line.

Figure-1

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2.2 Module-B: Activity description Quantity Remarks

Total number of plumb line segment 2 Refer figure-2 Total number of bends for plumb lines 6 Total number of tee joints 1 Total number of component assembly 4 Total number of welds including tube preparation. 6 Component welding will be carried out after DP, x r ay completion & clearance by LPSC team for the plumb line.

Figure-2

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2.3 Module-C: ACTIVITY DESCRIPTION QUANTITY REMARKS

Total number of plumb line segment 5 Refer figure-3 Total number of bends for plumb lines 7 Total number of tee joints 3 Total number of component assembly 7 Total number of weld including tube preparation. 16

Figure-3

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2.4 Module-D: ACTIVITY DESCRIPTION QUANTITY REMARKS

Total number of plumb line segment 03 Refer figure-4 Total number of bends for plumb lines 03 Total number of tee joints 06 Total number of component assembly 05 Total number of weld including tube preparation 16

Figure-4

Module-E:

F5

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ACTIVITY DESCRIPTION QUANTITY REMARKS

Total number of plumb line segment 5 Refer figure-5 Total number of bends for plumb lines 03 Total number of tee joints 06 Total number of component assembly 05 Total number of weld including tube preparation. 17

Figure-5

Note: The Figures shown above (1, 2, 3, 4 & 5) are indicative in nature. Actual dimensions will be provided at the time of realization.

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3.0 CONTRACT EXECUTION AND RESPONSIBILITIES: 3.1 The Contractor’s responsibilities The Contractor shall:

3.1.0 Carryout tube preparation for SS 304 L and Ti alloy (Ti6Al4V & Ti-Cp) material tubes of 6mm and 10 mm dia.(outside diam eter): 1. Cut the necessary tube length from the tube (provided by LPSCB team) using chip

less tube cutter as per the drawing.

2. Match the tube with the matting parts and bend it to the required shape as per the

drawing using the tube bender.

3. Apply positive gas (GN2) purging with a pressure of ~ 3 bars and square the other

end by means of tube squaring machine. Similarly square the other end also.

4. Deburr and dip the both the ends in the IPA and dry it by gas purging.

5. Check the ends with a magnifying glass and ensure burr free edges.

3.1.1 Carry out assembly of components and plumb lines:

1. Assemble the components and plumb lines identified by LPSCB team on the

template as per the reference drawing using the fasteners and spacers (provided

by LPSC team).

2. Record process critical dimensions of modules in the checklist as per the

drawing.

3. Module is cleared for welding after evaluation of dimensions by LPSC team.

3.1.2 Welding of the assembled components and plumb lines:

Contractor shall adopt standard procedure for welding SS 304 L and Ti alloy

(Ti6Al4V&Ti-Cp) material tubes of 6mm and 10 mm dia.(outside diameter).Propulsion

system welding will be cleared by LPSCB team on everyday basis after evaluation of

specimen (2 nos.) welded by party using set parameters as specified in procedure.

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3.2 The Departement’s responsibilities The Department’s shall be responsible for:

3.2.0 providing the identified area in clean room.

3.2.1 supplying raw material like SS tubes , standard component , module template,

integration accessories like tee joints, reducer , p clamps, fasteners and tools required

assembly of modules .

3.2.2 carrying our counter-verification of critical dimensions of modules.

3.2.3 weld specimen evaluation.

3.2.4 carrying out the testing of modules required for realization of modules.

3.2.5 clearance of Propulsion system modules.

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4.0 PROCESS FLOW CHART FOR REALISATION OF

PROPULSION SYSTEM MODULES

LPSCB Team: Pickled and passivated tubes, Argon gas, power and drawing.

Contractor: Tube cutting, bending and squaring as per the drawing @ LPSCB clean room

LPSC team: Welding clearance after evaluating critical dimensions of modules and weld specimen.

Contractor: Assembly of Components, Plumb line, integration accessories on template by as per the approved procedure.

List of items provided by LPSC: Flight components, Integration accessories, torque wrenches, tools and Module templates

Contractor: Welding of module elements at LPSCB clean room as per the procedure

LPSC Team: Testing and NDT (if applicable) clearance

NO

YES

Contractor: Rework as per approved procedure prapproved p

NO

List of items along with trained manpower provided by Contractor: Welding Machine, Tube bending machine, Tube cutter, Tube Squaring Machine, and Deburring tools.

Propulsion system modules

5.0 FACILITY REQUIREMENT:The Contractor shall equip them with all necessary equipments.also assure sufficient capacities to meet the throughput.minimum requirement. The list is not exhaustive. 5.1 Orbital TIG welding machine: An orbital TIG welding with inverter based power source (Max capacity: 170 amps) with shielding gas provision and real time monitoring and recording of weld parameters. S no. Specification Description

1 Power source Type Inverter based

2 OTIG of SS304L & Ti alloy

OD (mm) 6 X 0.7,

3 Real time monitoring and recording of weld output

Printout of actual weld parameters(voltage, current rotation , speed)

4 Power source cooling Forced Air

5 Manual gas control inputs Shielding gas

6 Weld electrode Ceriated tungsten electrode Lanthanated

7 Weld head: A:20-40 mm B:9-20 mm C: 45-60 mm Note: Weld head and power source should be of same manufacturer

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FACILITY REQUIREMENT: e Contractor shall equip them with all necessary equipments. The Contractor shall

also assure sufficient capacities to meet the throughput. The table below gives the minimum requirement. The list is not exhaustive.

Orbital TIG welding machine: bital TIG welding with inverter based power source (Max capacity: 170 amps) with

shielding gas provision and real time monitoring and recording of weld parameters.

Description

Inverter based

(mm) X Thickness(mm): , 6X1.0 & 10 X 0.7

Printout of actual weld parameters(voltage, current rotation , speed)

Forced Air

Shielding gas

Ceriated tungsten electrode or Lanthanated tungsten electrode.

Figure 1-Welding machine : Power source

Figure 2- Welding machine : Head

Figure 3-Welding machine: Gas pressure gauge (shielding gas)

The Contractor shall The table below gives the

bital TIG welding with inverter based power source (Max capacity: 170 amps) with shielding gas provision and real time monitoring and recording of weld parameters.

Welding machine : Power

Welding machine : Weld

Welding machine: Gas pressure gauge (shielding gas)

5.2 Tube Squaring machine:

Material Size in mm (OD X Thicknes

SS304L 6 X 0.7 & 10 X 0.7

Ti6Al4V/TiCp 6 X 1, 6 x 0.7

5.3 Deburring tools: Internal following tubes: Operation Material

Internal deburring (tube-ID )

Stainless steel

&

Titanium alloy External

deburring (tube-OD )

5.4 Hand Tube bender: Tube bending operations for the f ollowing tubes:

Material Size in mm

Stainless steel & Titanium alloy

6 mmX 15 mm Ben

10 mmX 24 mm Bend radius,

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Tube Squaring machine: Squaring operation for the following tubes

Size in mm (OD X Thicknes s )

6 X 0.7 & 10 X 0.7

Internal and External deburring operations for the

Size in mm

4.6 & 8.6

6 &10

Hand Tube bender: Tube bending operations for the f ollowing tubes:

Size in mm

Figure 5- Tube bender

6 mmX 15 mm Ben d radius,

10 mmX 24 mm Bend radius,

Figure 4-Tube squaring machine

Squaring operation for the following tubes

and External deburring operations for the

Hand Tube bender: Tube bending operations for the f ollowing tubes:

Tube bender

Tube squaring machine

5.5 Tube cutter: Tube cutting is carried out by using cutter overall length can be as minimum as 50 mm to meet the envelope constraint certain cases.

Material Size in mm (OD X Thickn ess )

Stainless steel

6 X 0.7 & 10 X 0.7,

Titanium alloy 6 X 1, 6 x 0.7

Note: Above mentioned equipment can vary in the size according to the company name and model number.

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Tube cutting is carried out by using CHIPLESS TUBE CUTTERcutter overall length can be as minimum as 50 mm to meet the envelope constraint

Size in mm (OD X ess )

6 X 0.7 & 10 X 0.7,

6 X 1, 6 x 0.7

Note: Above mentioned equipment can vary in the size according to the company

Figure 6- Tube cutter for normal cutting operation.

Figure 7- Tube cutter for cutting operations with envelope constraint

CHIPLESS TUBE CUTTER . Tube cutter overall length can be as minimum as 50 mm to meet the envelope constraint for

Note: Above mentioned equipment can vary in the size according to the company

Tube cutter for normal cutting

Tube cutter for cutting operations

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6.0 TOTAL WORK LOAD AND PERIOD OF CONTRACT:

During the period of contract work will be allocated on need basis. A minimum of 10

welds per day and maximum of 10 days of work shall be planned by the contractor.

The overall target for 1 year is 10 propulsion system per year i.e. 1000 welds . The

contractor shall ensure weld specimen is cleared by LPSCB team on daily basis before

execution of work for each type of tube. The contractor has to provide the specimen

free of cost as per the requirement mentioned above .

6.1 The contractor shall perform bending, cutting, edge preparation (for weld) and

welding (Orbital TIG) of SS 304L and Ti alloy tubes of OD: 6 mm 10 mm, with wall

thickness of 0.7 and 1 mm. The contractor shall plan for 750 welds per year under

this category.

6.2 The contractor shall perform only OTIG welds for the joints (SS 304L and Ti alloy

tubes of OD: 6 mm 10 mm, with wall thickness of 0.7 and 1 mm) prepared by LPSCB

team. The contractor shall plan for 250 welds per year under this category.

6.3 The period of contract will be for 1year.

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7.0 QUOTATION:

The quote shall contain Techno-Commercial Bid with price information. All relevant

supporting document proof to be provided along with the quote.

The contractor shall submit the price bid in format mentioned below:

Sl.

No. Description

Total units/year

(Numbers)

Rate/unit

(Numbers)

Total cost

(Rs)

*A B C = AXB

1

Tube bending, cutting

and welding (with edge

preparation)

750

2

Tube welding alone

excluding tube bending,

cutting and edge

preparation

250

Total cost

Note: *A is the total quantity required by LPSCB team in each category for 1 year of

contract.

8.0 PAYMENT TERMS:

100% payment within 30 days on presentation of invoice for the quantity of the work per

visit duly certified from the end –user and countersigned by division head on pro-rate

basis.

9.0 WARRANTY:

The Contractor shall carry out rework at their own expenses, the defects solely

attributable to faulty workmanship that may appear in propulsion system under this

contract.

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10.1.0 GENERAL GUIDELINES:

.

10.1.1 The Contractor must have handled similar activities at least for 2 years of similar

and identical works in ISRO/any other aerospace industry. Reference (Purchase

Order/Work Order/Contract copy) in support of shoul d be provided without which

the offer bid will not be considered.

10.1.2 The contractor has to provide the 3 numbers of weld specimen on their own

expense for evaluation on daily basis free of cost before the clearing the welding.

10.1.2 The contractor shall ensure that skilled technician to be deployed with an

experience of 2 years in handling similar kind of activity. Reference in support of

should be provided without which the offer bid will not be considered.

Deployment details of the personnel shall be maintained by the contractor. Proper

supervision, instruction and guidance shall be provided to the above personnel by the

contractor.

10.1.3 The Contractor shall be bound by the details furnished by him/her to LPSC while

submitting the tender or at any subsequent stage. In case, any of such documents

furnished by him/her is found to be false at any stage, it would be deemed to be a

breach of terms, making him/her liable for legal action besides termination of the

contract.

10.1.4 The contractor who has been awarded with the contract shall not be allowed to

transfer, assign, pledge or sub-contract its rights and liabilities under this contract to any

other agency without the prior written consent of LPSC.

10.1.5 LPSC being a High Security area, the contractor, if selected, will be required to

follow the security requirements such as possessing a valid pass/ID card for the

personnel while entering the campus, maintaining high order of discipline while on duty

and ensuring that only the personnel whose character and antecedents are verified

beforehand are employed.

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10.1.6 The Contractor shall equip them with all necessary equipments as mentioned in Section-5.0 of this document. Being a miniature kind of assembly the weld head dimensions given in the Section-5.1 should be adher ed. The Contractor shall also assure sufficient capacities to meet the throughput. Equipment and accessories of reputed manufacturer to be used for execution of wo rk and the contractor should provide the details of equipment and accessories as per the section-5.0.

10.1.7 All standard commercial terms and conditions of LPSC/ISRO, Government of

India shall be applicable.

10.1.8 LPSC shall be not be responsible for any damages, losses, claims, financial or

other Injury to any of the equipment / personnel deployed by the contractor in the

course of their performing the functions/duties, or for payment towards any

compensation.

11.0 CONFIDENTIALITY AGREEMENT:

The Contractor and personnel deputed by the Contractor shall not reveal, divulge,

transfer or disclose the information relating to the design, processes, fabrication

procedures, product, quality control methods, etc., that are exclusively provided by

LPSC for its (LPSC's) own requirements, to any third party. The Contractor shall not,

without prior written consent from LPSC, use such information for any purpose other

than for fulfilling obligations under the contract to be placed. The Contractor and the

personnel deputed by the Contractor undertake to restrict the access of non-Service

Provider personnel and other customers/visitors to LPSCB campus , to any of the job

being performed under this contract.

12.0 FALL CLAUSE:

The rates charged by the Contractor, shall in no event exceed the lowest rates charged

for the services of identical description, to any other party during the validity of the

agreed rates. If, at any time during said period, the Contractor reduces the rates for the

work to any other party, he shall forthwith notify such reduction of rates applicable to the

undersigned and the rates payable under this contract for the services shall stand

correspondingly reduced.

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Under no circumstances shall the personnel deployed by the Contractor claim any right

of employment, regular or otherwise, at ISRO/DOS and related establishments, during

and after the end of the contract period.

13.0 SECURITY DEPOSIT:

13.1 An amount equivalent to 10% of total order value in the form of Performance Bank

Guarantee (PBG) security deposit shall be remitted in favour of Sr Accounts Officer,

LPSC as Security Deposit towards completion of order. In case the contract is further

extended, the performance security will have to be accordingly renewed for the

extended number of units by the contractor.

13.2 Security Deposit will be released only after satisfactory completion of all

contractual obligations upon certification by the Focal point. No interest is payable on

Security Deposit / PBG amount.

14.0 SUMMARY:

The proposal document is for realization of propulsion system at different work centre of

ISRO i.e. LPSCB, ISAC & ISITE by external party to meet the project demand of 10

projects per year (1000 welds / year). The proposal covers assembly of flight

component and interconnection and welding its fluid interface i.e. SS 304L and Ti alloy

tubes of OD: 6 mm 10 mm, with wall thickness of 0.7 and 1 mm wall by employing OTIG

welding machine. The period of contract will be for 1year.

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END OF DOCUMENT