An nex ure ur e ‘B ’ Document No. : DRDL/DOAD/ATF/HWT/59 Copy No.
:
No. of pages
: 159 (including t itle page) page)
Design, si gn, Fa Fabricatio bri cation, n, Inst Insta alla ll ation ti on of of Wind in d Tunnel Syste Syst em and Commissioning ommissi oning of Hypersonic ypersonic Wind Tunnel un nel Fa Facili ci lity ty
Date of issue : May, 2013
EXECUTIVE SUMMARY
Defence Research and Development Laboratory (DRDL) proposes to establish one
meter
diameter
hypersonic
wind
tunnel
to
meet
research
and
development requirements for design of futuristic Hypersonic missiles and Re-entry vehicles which requires generation of extensive aerodynamic data. The facility w ill be built at Shamirpet (Badamafi), (Badamafi), Hyderaba Hyderabad. d. Hypersonic Wind Tunnel Facility consists of three major systems i.e, High Pressure System, Wind Tunnel System and and Vacuum System. High High pr essure system prov ides dry air at 300 bar and ambient temperature and vacuum system provides the required vacuum for various tunnel operating conditions. Wind Tunnel System provides the required flow conditions to be simulated for testing the models. For High Pressure System and and vacuum System, tendering tendering pr ocess is in progress. The current proposal is for Wind Tunnel System. The scope of work of Wind Tunnel System includes design/ realization and integration of Wind Tunnel System, integration of Wind Tunnel System with High Pressure System and Vacuum System on either side and commissioning of the entire Wind Tunnel Facilit Facilit y. Design, Design, realization realization and commis sionin g of High Pressure Pressure System and Vacuum System will be carried out in standalone mode by other vendors and will be made available available to Wind Tunnel System v endor. Necessary Necessary Civil works will be carried out by Department. Department would also provide input power to the Wind Tunnel Building from LT sub-station and utility water at nearest point. Entire work will be completed within a period of 48 months from the date of signing of contract. The document describes detailed specification, scope of work, acceptance tests of individual sub-system and Ac ceptan cep tance ce Test Tes t Pl an of o f t he enti en ti re f acili aci li ty .
2
EXECUTIVE SUMMARY
Defence Research and Development Laboratory (DRDL) proposes to establish one
meter
diameter
hypersonic
wind
tunnel
to
meet
research
and
development requirements for design of futuristic Hypersonic missiles and Re-entry vehicles which requires generation of extensive aerodynamic data. The facility w ill be built at Shamirpet (Badamafi), (Badamafi), Hyderaba Hyderabad. d. Hypersonic Wind Tunnel Facility consists of three major systems i.e, High Pressure System, Wind Tunnel System and and Vacuum System. High High pr essure system prov ides dry air at 300 bar and ambient temperature and vacuum system provides the required vacuum for various tunnel operating conditions. Wind Tunnel System provides the required flow conditions to be simulated for testing the models. For High Pressure System and and vacuum System, tendering tendering pr ocess is in progress. The current proposal is for Wind Tunnel System. The scope of work of Wind Tunnel System includes design/ realization and integration of Wind Tunnel System, integration of Wind Tunnel System with High Pressure System and Vacuum System on either side and commissioning of the entire Wind Tunnel Facilit Facilit y. Design, Design, realization realization and commis sionin g of High Pressure Pressure System and Vacuum System will be carried out in standalone mode by other vendors and will be made available available to Wind Tunnel System v endor. Necessary Necessary Civil works will be carried out by Department. Department would also provide input power to the Wind Tunnel Building from LT sub-station and utility water at nearest point. Entire work will be completed within a period of 48 months from the date of signing of contract. The document describes detailed specification, scope of work, acceptance tests of individual sub-system and Ac ceptan cep tance ce Test Tes t Pl an of o f t he enti en ti re f acili aci li ty .
2
Contents: Executive summary ……………………………………………………………… ………………………………………………………………..
2
Nomenclature
6
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Chapter 1 Intro duc tio n and sco pe of wor k
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10
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10
1.1 Scope and description descriptio n ……………………….…………………………… ……………………….……………………………….. …..
13
1.2 Duration
15
1.0 Introduction Introduct ion
………………………………………………………………... ……………………………………………………………….
1.3 Description of the overall facility and process
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15
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18
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18
1.4 Location and layout of the facility 1.5 Scope of contract
Chapter 2 Press ure Regulat ing in g Syst em 2.0 Introduction Introducti on
…………………… …………………………… ………….. …..
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29 29
2.1 Pressure regulating system objectives and configuration configurati on ………………
30
2.2 Scope of Work ……………………………………………………………….
31
2.3 Specifications Specificati ons
35
………………………….………………………………………. ………………………….…………………………… ………….
2.4 Acceptance tests
……………………………………………………….
39
2.5 Functional test
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42
2.6 Documentation ……………………………………………………………….
42
2.7 Deliverables
44
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Chapter 3 Air Ai r Heating Syst em 3.1 Introduction Introducti on
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3.2 Major work definition
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3.3 Technical specification specificati on 3.4 Deliverables
49 49 49
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52
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73
Chapter 4 Tunn el System Sys tem 4.0 Introduction Introducti on
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75 75
4.1 Settling Chamber
………………………………………………………….
75
4.1.1 Introduction Introduct ion
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75
4.1.2 System configuration configurat ion ……………………………………………………….
76
4.1.3 Technical specification specificati on
77
4.1.4 Acceptance test 4.2 Nozzles
……………………………………………….
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83
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83
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83
4.2.1 Introduction Introduct ion
4.2.2 System configuration configurat ion ……………………………………………………. …………………………………………………….……. …….
83
4.2.3 Technical specification specificati on
86
4.2.4 Acceptance test 4.3 Test Section 4.3.1 Introduction Introduct ion
……………………………………………….
……………………………………………………………..
……………………………………………………… …………. …………………………………………………………………. ………………………………………………………… 3
89 90 90
4.3.2 System configuration ……………………….………………………………….
90
4.3.3 Technical specification
91
4.3.4 Acceptance test
……………………………………………….
……………………………………………………………..
94
4.4 Model Incidence Mechanism ……………………………………………….
94
4.4.1 Introduction
94
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4.4.2 System configuration …………………………………….………………….
95
4.4.3 Technical specifications
97
4.4.4 Acceptance test 4.5 Diffuser
……………………………………………….
……………………………………………………………..
99
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99
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99
4.5.1 Introduction
4.5.2 System configuration ……………………………………………………………. 4.5.3 Technical specification 4.5.4 Acceptance test
……………………………………………….
…………………………………………………………….
4.6 Vacuum Isolation Valve
……………………………………………………
99 100 106 106
4.7 Connecting duct
……………………………………………………….
106
4.7.1 Introduction
…………………………………………………………
106
4.7.2 System Configuration
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4.7.3 Technical specification 4.7.4 Acceptance test 4.8 Aftercooler
……………………………………………….
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4.8.1 Introduction
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4.8.2 Functional requirement and specifications 4.8.3 Inspection & Testing
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4.9 Scope of work for tunnel system 4.10 Deliverables
107 108 108 108 109 113
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115
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119
Chapter 5 Inst rum entatio n and con tro l sys tem 5.0 Introduction
…………………………….
106
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5.1 Facility Description
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5.2 Tunnel operating sequence
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5.3 Functional requirement of instrumentation system 5.4 Indicative block diagrams
…………………
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120 120 120 121 122 126
5.5 Instrumentation system components requirement ……………………………
129
5.6 Software ………………………………………………………..…………………
142
5.7 Scope of work by Contractor ……….………………………………………
143
5.8 Scope of work by Department
………….……………………………
143
5.9 Installation and Commissioning …………………………..…………………
144
5.10 Documentation
……………….………….……………………………
144
5.11 Acceptance test plan ………….…………………………..…………………
144
4
5.12 Deliverables
………………………………………………………………..
Chapter 6 Accept ance Test Plan
……..………..................................
5
145 159
Nomenclature: α
Pitch angle
β
Yaw angle
φ
Roll angle
ADC
Analog to Digital Converter
AF
After cooler
AHS
Air Heating System
AISI
American Iron and Steel Institute
ANSI
American national standard institute
AOUT
Analog Out
API
American petroleum institute
ANALOG IN
Analog Input
ASME
American Society of Mechanical Engineers
ASTM
American Society for Testing Materials
BS
British standards
BVIS
Bureau Veritas Industrial Services Pvt Ltd
CCE
Chief Controller of Explosives
CD
Compact Disc
COTS
Commercially-off-the-shelf
CS
Carbon Steel
D
Diffuser
DAQ
Data Acquisition
DAC
Digital to Analog Converter
Db
Bed outer diameter
DER
Detailed Engineering Review
Di
Insulation outer diameter
DIG IN
Digital IN
DIN
Digital IN
DIG OUT
Digital Out
DOUT
Digital Out
DMR
Double Mode Redundancy
DN
Nominal diameter
DNV
Det-Norske Veritas
Ds
Shell outer diameter 6
EGV
Electro Pneumatic / Electro Hydraulic Globe Valve
EH
Electro Hydraulic
EIL
Engineers India Limited
EMI
Electro Magnetic Interference
EMC
Electro Magnetic Compliance
EP
Electro Pneumatic
FCI
Fluid Control Institute
GUI
Graphical User Interface
H
Heater
HMS
Health Monitoring System
HP
High Pressure
HPS
High Pressure System
HSV
Hot Shutoff Valve
HT
High Tension
HWT
Hypersonic Wind Tunnel
INR
Indian National Rupees
LEL
Lower explosive limit
LPG
Liquefied Petroleum Gas
LRIS
Lloyds Register Industrial Services Pvt Ltd
LT
Low tension
M
Mach Number
MAWP
Maximum allowable working pressure
MBV
Manual Operated Ball Valve
MCC
Motor Control Centre
MCS
Master Control System
MFA
Model Free Adaptive
MICS
Model Incidence Control System
MIM
Model Incidence Mechanism
MS
Measurement System
MT
Metric tones
MTBF
Mean time between failures
MVWSS
Medium Velocity Water Spray Sprinkler
N
Nozzle
NDT
Non Destructive Testing 7
NPS
Nominal Pipe Size
OISD
Oil industry safety Directorate
P & ID
Process & Instrumentation Diagram
PDR
Preliminary Design Review
PID
Proportional Integral Differential
PIV
Particle Image velocimetry
PLIF
Planar laser induced fluorescence
PM
Pressure Measurement
PP
Perforated plate
Pr
Pressure
PRCS
Pressure Regulating Control System
PRS
Pressure Regulating System
PRV
Pressure Regulating Valve
PSP
Pressure Sensitive Paint
PT
Pressure Transducer
QAP
Quality assurance plan
QC
Quality Control
Re
Reynolds Number
ROV
Remotely Operated Valves
RT
Radiography Test
RTD
Resistance Temperature Detector
RTDAS
Real Time Data Acquisition System
RTOS
Real Time Operating System
RTJ
Ring type joint
SC
Settling Chamber
SCADA
Supervisory Control & Data Acquisition
SNR
Signal to Noise Ratio
SS
Stainless Steel
STP
Shielded Twisted Pair
TC
Thermocouple
TEMA
Tubular Exchanger Manufacturers association
TM
Temperature Measurement
TMR
Triple Mode Redundancy
TPIA
Third party inspection agency 8
TS
Test Section
UPS
Uninterrupted Power Supply
VG
Vacuum Gauge
VIV
Vacuum Isolation Valve
VPV
Vacuum Pump Valve
VS
Vacuum System
VTA
Vent to Atmosphere
9
CHAPTER 1 Introduction and Scope of work 1.0 INTRODUCTION – Defence Research and Development Laboratory (DRDL) (hereafter referred as Department) proposes to establish a 1.0 m diameter hypersonic wind tunnel in order to cater to the ever-growing ground testing requirements for various hypersonic vehicle configurations which are currently at different stages of design and development and also for futuristic configurations. The facility will be built at Hyderabad. Hypersonic Wind tunnel Facility consists of High Pressure System, Wind Tunnel System and Vacuum System. High pressure system provides dry air at 300 bar and ambient temperature and vacuum system provides the required vacuum for various tunnel operating conditions. Tunnel System provides the required flow condition to be simulated for testing the models. The regulated air at ambient temperature is heated to a higher temperature as the air passes through an air heater. The model is injected into the test section after stabilization of the flow using a model incidence system.
Further downstream the flow
passes through diffuser system and it is cooled to a lower temperature by an after cooler before being dumped into the vacuum tank. The model is retracted after the measurements are completed and after that tunnel blow down is stopped. The typical useful blow down time is 20 - 40 seconds.
Broad specifications of the wind tunnel are given in Table 1.1. The operating envelope is given in Table 1.2. Overall layout of the Wind Tunnel with High Pressure System and Vacuum System is shown in Fig 1.1.
10
Table 1.1
: Broad specifications of the Hypersonic Wind Tunnel
Nomenclature
Description
Type of Wind Tunnel
Pressure-Vacuum enclosed free jet
Test medium
Air
Nozzle exit diameter (nominal)
1.0 m
Mach number
5, 6.5, 8, 10 and 12
Stagnation pressure (bar)
10 - 100
Stagnation temperature (K)
346 -1400
Vacuum level (mbar)
0.01
Mass flow rate (kg/sec)
0.7 - 180
Minimum run time (sec)*
20
Maximum number of tests per day
4
Types of tests
Force, Pressure, Flow visualization (Schlieren, oil flow)
* Run time - Useful test time excluding flow settling time of approximately 20 sec
Table 1.2 : Operating Envelope of Hypersoni c Wind tunnel
Highest end of Test Envelope
Mach
Lowest end of Test Envelope
P0
T0
Mass f low rate
P0
T0
Mass f low rate
(Bar)
(K)
(kg/sec)
(Bar)
(K)
(kg/sec)
5
30
376
180
10
346
61.38
6.5
100
575
152.4
10
487
16.6
8
100
760
60.6
10
653
6.5
10
100
1046
18.3
10
912
2
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
Air Heating system LPG storage
High pressure system
Measurement system
Cooling towers
Vacuum Pumps
Tunnel System
Compressors
Pressure regulating system High Pressure storage tanks
Tunnel Control system
Vacuum spheres
W ind tunnel system Vacuum system Vacuum sphere
HEATER
N oz zle Test Section Settling chamber
Vacuum isolation valve After cooler
Model Incidence Mechanism
Hot shut
Fig. 1.1
Diffuser
Layout Of DRDL Hyperson ic Wind Tunnel 12
1.1 SCOPE A ND DESCRIPTION The realization of Wind Tunnel is to be executed on turnkey basis. The scope of work, description, functional requirements and technical specifications of each sub-system, terms and conditions for executing the contract, etc, are given in this tender document. The above details have been brought out for different sub-systems chapter wise as given below. Chapter 2 – Pressure Regulating System Chapter 3 – Air Heating System Chapter 4 - Tunnel System Chapter 5 – Instrumentation and Control System Some of the key words used in this document are defined as follows. •
“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
GL
1.1 SCOPE A ND DESCRIPTION The realization of Wind Tunnel is to be executed on turnkey basis. The scope of work, description, functional requirements and technical specifications of each sub-system, terms and conditions for executing the contract, etc, are given in this tender document. The above details have been brought out for different sub-systems chapter wise as given below. Chapter 2 – Pressure Regulating System Chapter 3 – Air Heating System Chapter 4 - Tunnel System Chapter 5 – Instrumentation and Control System Some of the key words used in this document are defined as follows. •
“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.
•
“Facility” shall mean the proposed Hypersonic Wind Tunnel Facility.
•
All the pressure values specified in this document are in absolute scale, unless specified otherwise. 13
1.1.1 MAJ OR WORK DEFINITION (i)
Design, detailed engineering, fabrication/procurement, inspection and testing, supply, integration and commissioning of the wind tunnel consisting of the following sub-systems. a) Pressure Regulating System consisting of pressure regulating valves, other valves and associated pipelines. b) Air Heating System including heaters, hot shut-off valves, burner-blower, chimney, LPG storage tank, associated pipeline, instrumentation and control for heating operation. c) Other tunnel systems such as Settling Chambers, Nozzles, Test Section, Model Incidence Mechanism, Diffuser, Connecting Duct, After Cooler. d) Wind tunnel cooling systems and integration with the respective wind tunnel component.
(ii)
Design, realization and commissioning of High Pressure System and Vacuum System will be carried out by other vendors and will be made available to Wind Tunnel System vendor. Wind Tunnel System vendor has to integrate Wind Tunnel System with High Pressure System and Vacuum System on either side
(iii)
Design and realization of instrumentation & control system according to the requirement given in the document.
(iv)
Integration of sensors, instruments with wind tunnel systems and development and supply of software for wind tunnel operation and control.
(v)
Import, supply and integration of vacuum isolation valve.
(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)
Integration of different sub-systems of Wind Tunnel System
(xi)
Integration of Wind Tunnel Systems with High Pressure System and Vacuum System on either side.
(xii)
Commissioning of Wind Tunnel
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 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.
1.3 DESCRIPTION OF THE OVERALL FACILITY AND PROCESS 1.3.1 DESCRIPTION OF THE FACILITY The tunnel is of intermittent type and uses air as working fluid. The facility would be used to carry out aero thermal studies of model at different flow conditions. A block diagram of wind tunnel is given in Fig 1.2. 1.2. The major systems that constitute the tunnel are: 1. High pressure system (HPS) 2. Wind Tunnel System •
Pressure regulating system (PRS)
•
Air Heating system
•
Tunnel System
•
Instrumentation and Control System
3. Vacuum System (VS) 4. Schlieren System 5. Civil and Electrical Infrastructure The High pressure system comprises of air compressor system, high-pressure air storage, valves, piping and will be used to compress air to required storage pressure. The Pressure Regulating System will be used for pressure reduction from high pressure storage to the required test pressure in settling chamber. chamber. The heater is used to heat the air to the required temperature. Without heating, the air expanding in the tunnel nozzle to high velocity will be cooled to such low temperatures, which results the air to liquefy. Storage heater (cored brick bed) is proposed. The heater bed is heated by combustion products products from a burner. 15
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.
1.3.2 WIND TUNNEL WORKING WORK ING PROCESS The Typical sequence of operations for one blow-down is as follows: Atmospheric air is compressed, dried, recompressed and charged into the high-pressure air storage vessels. Simultaneously the cored bed heater is heated-up with combustion products from a burner and the vacuum spheres are evacuated by the vacuum pumps. When the required initial storage pressure is reached in the pressure vessels, the pressure regulating unit is set for the required test pressure in settling chamber. When all the systems are ready, the blowdown starts. Air is supplied from the pressure vessels at a pressure regulated by the pressure regulating system and is heated as it flows through the heater. When the pressure in the heater reaches a specified value, a valve downstream of heater is opened and hot air passes through the settling chamber. The high-pressure, high-temperature air then expands through a nozzle to give the required controlled environment in the test section. The model to be characterized is injected into the test section. The air flows around the model in the test section. After the test section air is decelerated in a diffuser and passes through after cooler and collected into the vacuum spheres. When the pressure in the vacuum spheres reach a specified level the blow-down is stopped. The cycle of operations is repeated. The duration of blow-down is 20 seconds. Four tests are planned per day.
1.3.3 DESCRIPTIONS OF WIND TUNNEL SYSTEM The block diagram of the facility as shown in Fig. 1.2 brings 1.2 brings out the major subsystems of the facility. The major subsystems of Wind Tunnel System are as follows: •
Pressure Regulating System
•
Air heating system
•
Tunnel system
•
Instrumentation and control system 16
Wind tunnel system is integrated to the High Pressure System in the upstream side and Vacuum System in 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 conditions in the test section.
High Pressure System - Block A of Fig. 1.2: The high pressure system consists of storage tanks of 80 m 3 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.
Ai r Heatin Heat in g Sy st em – B lo ck B of o f Fig. 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 Syst em – Block D of Fig. 1.2: 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 m 3 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.
1.4 LOCATION AND LA Y-OUT OF THE FACILITY The facility will be established at Shamirpet (Badamafi), Hyderabad, Andhra Pradesh, India. The nearest seaport is at Chennai, which is 700 km away towards the south-east. Nearest airport is at Shamshabad, Hyderabad.
1.4.1 LAY-OUT OF THE FACILITY The equipment layout of the facility is given in Fig. 1.3. 3-D layout of Wind Tunnel Complex is given in Fig. 1.4
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 SCOPE OF SERVICES BY THE DEPARTMENT In order to realize individual system, the Department will provide the following services:
1.5.1.1
PRELIMINARY DESIGN & DESIGN REVIEW 18
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 LA Y-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
REVIEW OF DETAILED ENGINEERING
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
MAJOR CIVIL WORKS
The Department will carry out the following major civil works: •
Site preparation and road
•
Building and trenches
•
Foundation with pockets for equipments
•
Lighting and PH 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
SERVICES DURING ERECTION AND COMMISSIONING
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
The instrumentation (measurement/command/control) for the individual system shall be realized by the Contractor.
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.
Supplying & laying of the cable (Armoured XLPE cable
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.
1.5.2 SCOPE OF WORK BY CONTRACTOR The scope of work to be done by the Contractor for the realization of Wind Tunnel System is given in this section. The bidder is required to submit a complete quotation for the entire works mentioned herein. If required, the Contractor may engage Sub-Contractors for executing part of the work. However, prime Contractor will be solely responsible for completion of the work. The bidder shall provide in the quotation, the list of Sub-Contractors proposed to be engaged for approval by the Department.
20
1.5.2.1 PRELIMINARY DESIGN The tentative P & IDs, sizing of wind tunnel components are given in this document. Upon award of the contract, the Contractor shall carry out preliminary design of the various systems and submit a design document containing details, with calculations of the sizing of the tunnel circuits, comprising the pipe-lines, valves, tunnel components, instruments, etc. within a period of two months. The Department will organize Preliminary Design Review (PDR) meeting at the Department within a period of one month from submission of Preliminary Design Document in which the Contractor’s representatives will participate. The objective of the design review is to arrive at a consensus between the Department and the Contractor on the design of Wind Tunnel System to freeze the input data for the detailed engineering to be done by the Contractor. The design shall be generally as per the configuration given in respective chapters of this document and shall meet the objective specification. The design calculations are to be based on the codes/standards mentioned in various section of this document. In such cases where the Contractor uses alternative codes/ standards, it shall be their responsibility to submit a copy of such codes/ standards in English language to the Department during design review. The design review shall primarily address the following issues: •
Design of Wind Tunnel System to comply with the specified functional requirements as given in respective chapter of this document.
•
Adequacy of the size of pipelines, valves, tunnel components, instruments, etc to comply with the specified process parameters.
•
Adequacy of the in-built safety features.
1.5.2.2 DETAILED ENGINEERING Based on the Preliminary Design approved by the Department in Preliminary Design Review (PDR), the Contractor shall carry out detailed engineering, which shall comprise the following. a. Detailed pipe line layout shall be made. The 3-dimensional isometric drawings of the individual pipe-line segment shall be made and the necessary pipe stress analysis shall be carried out. Pressure drop and temperature drop along the pipe need to be estimated. b. Detailed thermo-structural analysis will be carried out for all the tunnel components like heater, associated downstream pipes, Settling Chambers, nozzles, Test Section, Model Incidence Mechanism, Diffuser, Connecting Duct and After Cooler. Based on thermo-structural analysis, material will be finalized. 21
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
commissioning shall be worked out based on mutual discussion between Contractor and the Department. e. Detailed
procedure
and
acceptance
criteria
for
fabrication,
erection
and
commissioning shall be provided for approval. f.
Civil and Electrical requirements: The equipment lay-out of the wind tunnel facility, showing the major civil works to be done by the Department, is given in the drawing. During the Detailed Engineering Review (DER), the Contractor shall provide the additional details to be incorporated in the major civil works such as foundation pockets, forces & moments acting on the foundation, etc. The revised equipment layout showing such fine details shall be made by the Contractor. The load details of electrical power shall also be provided.
g. The details regarding the space requirement, water equipments shall be given by the Contractor. h. The purchase specification of the materials such as equipments, tunnel components, instruments, pipes; pipe fittings, valve, etc shall be provided. i.
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 list of spares to be supplied shall be provided.
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 Department’s site within two weeks after the submission of document. Contractor’s 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 Contractor’s 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 Contractor’s factory and erection at the Department’s site shall be inspected by one of the following reputed Third Party Inspection Agencies (TPIA). •
Lloyds Register Industrial Services Pvt Ltd (LRIS)
•
Bureau Veritas Industrial Services Pvt Ltd (BVIS)
•
Det-Norske Veritas (DNV)
•
Any other Govt. approved Agency
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 Contractor’s 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 Department’s 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 Department’s site at Hyderabad.
1.5.2.9
ERECTION
The system is to be erected by the Contractor at the Department’s site. Apart from erecting the system fabricated by the Contractor, it shall also be the Contractor’s 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 Contractor’s personnel shall not be permitted to reside inside the Department’s 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
it shall be the Contractor’s responsibility to translate them to English language. The documents shall also be provided in CDs, besides the 3 hard copies. These documents are subject to review by the Department. However, the Department’s approval shall not absolve the Contractor’s responsibility to comply with the specifications and obligations of the contract. The list of documents to be provided by the Contractor at different phases of the contract for different system is given in respective chapter.
25
BLOCK - A
BLOCK - B BURNER SYSTEM
VALVE OPERATING SYSTEM
CHIMNEY
BLOCK - C
COOLING WATER
M = 10 & 12 EGV7
EGV4
EGV5
PRV3
SYSTEM
7 V S H
5 V S H
MBV3
SETTLING
M = 5 & 6.5
PRV1
M = 5 & 6.5
H1 M = 8, 10 & 12
SYSTEM
EGV6
PRV2
COOLER VIV
M = 8, 10 & 12
VACUUM
H2
MBV2
M=8
AFTER TEST SECTION
HSV2
HSV1
M = 5 & 6.5
SCHLIEREN & I R SYSTEM
CHAMBER1
MBV1
STORAGE
HIGH PRESSURE
BLOCK -D
VENT
SPHERE
HSV4
HSV3
8 V S H
6 V S H
SETTLING CHAMBER2
NOZZLE
CHIMNEY
DIFFUSER VACUUM SYSTEM
MIM SYSTEM
ELECTRICAL SYSTEM
MIM
VENT
TEST SECTION EVACUATION SYSTEM
BLOCK - E TC 3
TC 2
TC 1
TC 4
TC MAIN BLOCK - A : HIGH PRESSURE SYSTEM BLOCK - B : AIR HEATING SYSTEM BLOCK - C : TUNNEL SYSTEM BLOCK - D : VACUUM SYSTEM BLOCK - E : TUNNEL CONTROL SYSTEM
TC HSV PRV VIV MBV
:Tunnel CONTROL : Hot Shutoff Valve : Pressure Regulating Valve : Vacuum Isolation Valve : Manual Ball Valve
M = 5, 6.5 PRV lin e M = 8 PRV line M = 10 & 12 PRV line
Fig 1.2 Block diagram of Hypersonic Wind Tunnel
26
m 0 5 1
Heater1
Compressors Heater2
High Pressure storage tanks
m 0 5 1
Heater1
Compressors Heater2
High Pressure storage tanks
300m
Fig 1.3 Equipment layout of wind tunnel 27
CHIMNEY EXPANSION BELLOW
DIFFUSER TEST SECTION
CONNECTING DUCT VACUUM SHPERE
PRS
NOZZLE SETTLING CHAMBER
CHIMNEY EXPANSION BELLOW
DIFFUSER TEST SECTION
CONNECTING DUCT VACUUM SHPERE
PRS
NOZZLE SETTLING CHAMBER
HEATER SHED WITH HEATER AND PLATFORM
AIR STORAGE
Fig 1.4 Layout of wind tunnel complex 28
CHAPTER 2 Pressure Regulati ng System 2.0 INTRODUCTION The main function of the Pressure Regulating System (PRS) is to reduce the high-pressure air stored in the air storage at 300 bar (g) to the required test pressures to be maintained in the settling chamber within specified accuracy to meet different test conditions. The system shall be capable of supplying air at varying mass flow ranging from 0.7 kg/s to 180 kg/s and test pressure from 10 bar to 100 bar depending on the test requirement. The scope of the work includes the sizing of the system, engineering of the system, procurement of various standard components/sub systems, fabrication of pipeline etc., erection, commissioning at site (Hyderabad), testing and demonstration of the performance, training and handing over for normal operation. The PRS consists of the following sub-systems/components: •
Pressure Regulating Valve
CHAPTER 2 Pressure Regulati ng System 2.0 INTRODUCTION The main function of the Pressure Regulating System (PRS) is to reduce the high-pressure air stored in the air storage at 300 bar (g) to the required test pressures to be maintained in the settling chamber within specified accuracy to meet different test conditions. The system shall be capable of supplying air at varying mass flow ranging from 0.7 kg/s to 180 kg/s and test pressure from 10 bar to 100 bar depending on the test requirement. The scope of the work includes the sizing of the system, engineering of the system, procurement of various standard components/sub systems, fabrication of pipeline etc., erection, commissioning at site (Hyderabad), testing and demonstration of the performance, training and handing over for normal operation. The PRS consists of the following sub-systems/components: •
Pressure Regulating Valve
• Actuators •
Power packs for actuators
•
Servo valves
• Sensors •
Associated valves and piping
•
Electrical and Control System
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 Contractor’s scope of work shall include the following: •
Detailed design of all the components of PRS.
•
Detailed engineering of the entire PRS and generation of purchase specifications.
•
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 Contractor’s factory.
•
Transportation of materials to and storage at the Department’s site.
•
Erection, testing and co-ordination for inspection of the entire system at the Department’s site.
•
Commissioning of the PRS and demonstration of performance in wind tunnel.
29
2.1
PRESSURE REGULATING SYSTEM CONFIGURATION
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.
Functional Requirement- The functional requirements of Pressure Regulating System are given below. •
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.
•
Response of the system should be less than 5 sec.
•
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
Mass flow rate in kg/s for different test cases Mach 5
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 Department’s 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 welder’s 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.
2.2.5 SUPPLY OF SPARES The following spares shall be supplied by the Contractor along with the PRS. The break-up prices of the spares shall be given in the quotation. I.
Spare parts and consumables for erection and commissioning: the Contractor shall supply the spare parts (like seat insert, body gasket, gland packing, plug/stem assembly, etc for valves), sensors, etc to be replaced/ used during erection and commissioning 33
II.
Spare parts and consumables for operation and maintenance: The Contractor shall also supply the spare parts (like seat insert, body gasket, gland packing, plug stem assembly with bellows, etc for valves), sensors etc to be replaced/ used during operation and maintenance over a period of 2 years from commissioning. The constituents and quantity of such spare parts shall be worked out, considering the causative factors such as normal wear & tear, fatigue cycles, creep, Mean Time Between Failures (MTBF), etc. The spare parts allocated for this purpose shall not be consumed by the Contractor during erection and commissioning. The vendor shall also submit a list of source for purchasing spare for future requirements.
2.2.6 ERECTION The system is to be erected by the Contractor at the Department’s site. Apart from erecting the system fabricated by the Contractor, it shall also be the Contractor’s 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 Contractor’s personnel shall not be permitted to reside inside the Department’s 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
The specifications for various components of PRS are given below
2.3.1 SPECIFICATION FOR PRESSURE REGULATING VALVE (PRV) The control valve shall comprise valve, position sensor, actuator and hydraulic power pack. Pattern
:
Single ported Globe valve
(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
:
BS 6755/ BS 5155/ API 598/ B16.34
Material (body)
:
ASTM A216 grade WCB/ A 182 F304L
Pressure class
:
Class 2500
End connection
:
Flanged class 2500 RF with RTJ
Permissible leak rate across
:
Class IV as per ANSI B 16.104 / FCI 70.2
Size
:
2”, 4” and 12”
Trim characteristics
:
Equal percentage characteristics (Installed)
Working temperature
:
200-310K
Max. Working pressure
:
330 bar
seat
Allowable Pressure variation in test pressure
: ±1% of set pressure
Run time
:
40 sec.
Control algorithm
:
Suitable control (PID/ MFA/ Fuzzy Logic etc)
Servo valve redundancy
:
Three level
Safety
:
Fail to close
Allowable noise
:
Less than 85 dBA
Actuator
:
Electro hydraulic with power pack & servo Valves, positioner, position transmitter
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
Tentative lis t of Pressur e Regulating Valve Operating Conditioning
Valve
Nominal Valve size
Type of valve
Temperature
MAWP
(K)
(MPa)
PRV1
200-310
33
12”
Globe
PRV2
200-310
33
4”
Globe
PRV3
200-310
33
2”
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.
ii) POSITION SENSORS Position sensors shall be provided for indicating the percentage opening of the PRV. Triple mode redundancy is to be provided for these sensors. For increasing reliability, different sensors like potentiometer/LVDT, encoder may be employed. Apart from these sensors, a local position indicator (with a pointer and graduated scale) shall be provided.
2.3.2 MANUALLY OPERATED VALVE: Table 2.3 Valve Tag no.
Lis t of manually operated valves Operating Conditioning
Temperature (K)
Nominal Valve
MAWP
Size (Inches)
Type of valve
(MPa)
MBV1
200-310
33
12”
Ball
MBV2
200-310
33
4”
Ball
MBV3
200-310
33
2”
Ball
Tag no, pattern, working temperature range, Size, MAWP are given above in Table 2.3 Actuation
:
Hand operated (Manual)
Application
:
Isolation
Permissible leak rate
:
1. Class IV as per ANSI B16.104/FCI 70.2 standard for globe valve.
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
:
Flanged ends as per ANSI B 16.5
:
with full port (standard bore) and in-line end
Style of construction Body
connections Bonnet
:
Bolted or screwed to body
Stem
:
Quarter turn stem for Ball Valves
Stem (dynamic) seal
:
By gland packing for Globe, Ball Valves.
Plug
:
Renewable (replaceable) from stem.
Seat
:
Renewable from body with seat insert.
Flow direction
:
Flow to open
Cycle of operation
:
10,000 cycles
MOC (Body)
:
ASTM A216 Gr. WCB/ A 182 F304L
Design code
:
1. BS 5352/ BS 6364 / API 6-D/ANSI B 16.34 for globe valves. 2. BS 5351 for ball valves
Test code
:
BS 6755/ BS 5155/ API 598/ B16.34
Suitable limit switches shall be provided for indicating the extreme position of the valve (i.e, fully open & fully closed position)
2.3.3 ELECTRO-PNEUMATIC/ ELECTRO–HYDRAULIC GLOB E VALVES (EGV) The electro-pneumatic/electro-hydraulic Globe valve (EGV) shall comprise the valve, actuator, solenoid valve and limit switches. i)
Valve
Actuation
:
Electro-pneumatically/Electromechanically operated
(Tag no., working Temperature range, Size, MAWP As given in Table 2.4) Table 2.4 Valve
Electro -Pneumati c/ Electro -hydraul ic Valves Operating Conditions
Nominal
Type of
Mode of
valve
Operation
Temperature
MAWP
Valve si ze
(K)
(MPa)
(Inches)
EGV5
200-310
33
12”
Globe
EP/EH
EGV6
200-310
33
4”
Globe
EP/EH
EGV7
200-310
33
2”
Globe
EP/EH
Tag no.
37
ii) Actuator Type
:
Linear actuator, piston/diaphragm type, single acting, Spring return.
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
Nominal pipe size & Schedule number
:
as per P & ID
Length
:
As required based on the isometrics to be prepared by the Contractor.
Material
:
ASTM A 312 TP 304L for all circuits.
Dimensional standard
:
ANSI B 36.19/36.10
2.3.5 PIPE FITTINGS: Size & pressure rating
:
As required based on P&ID and isometric drawings to be prepared by the Contractor.
Type
:
Butt welded fittings for fluid circuits size ≥ DN 50 Socket welded fittings for fluid circuits size ≤ DN 40
Flanges
:
ANSI B 16.5
Butt welded fittings
:
ANSI B 16.9
Socket welded fittings
:
ANSI B 16.11
Material for fittings to be used in SS pipeline 38
Flanges
:
ASTM A 182 F 304L
Butt welded fittings
:
ASTM A 403 WP 304L
Socket welded fittings
:
ASTM A 182 F 304L
2.3.6 SAFETY SYSTEM A suitable safety device with adequate redundancy shall be installed downstream of pressure regulating system to safe guard the system. A suitable vent pipe with an electropneumatic valve is to be provided downstream of pressure regulating system to let out the trapped air from the pipeline when the upstream and downstream valves in this line are closed in case of emergency. The vent pipe shall be routed outside of the shed.
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 tes t: 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 s eat t est (for b all 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:
One specimen from each lot shall be subjected to detailed
chemical analysis as per ASTM A 751. iv) Mechanical tests: One specimen from each lot shall be subjected to tests for mechanical properties as per ASTM A 370 (including impact test). v) Hydraulic pressure test: All pipes shall be hydraulically pressure-tested with water as per ASTM A 530. vi) Ultra-sonic test: All the SS pipes of size ≤ DN 25 shall be subjected to Ultra-sonic test (100%) by contact method as per ASTM A 450. vii) Eddy current test: All the SS pipes of size ≤ DN 15 shall be subjected to Eddy current test as per ASTM E 426. viii) 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 in steps to prove ductility and soundness. ix) Inter-granular corrosion test: One specimen per lot shall be subject to inter-granular corrosion test as per ASTM A 262 (practice A/E). x) Cleanliness: The pipes shall be cleaned and dried before dispatch. xi) Marking: The pipes shall be marked as per ASTM A 700.
2.4.3 PIPE FITTINGS The following tests have to be conducted on pipe fittings: i) Visual examination: All fittings shall be visually examined for any scratches, dents, and surface irregularities etc. ii) Dimensional check: One specimen from each lot shall be subjected to dimensional check. iii) Chemical analysis: On specimen from each lot shall be subjected to detailed chemical analysis as per ASTM A 751. iv) Inter-granular corrosion test: One specimen per lot shall be subjected to intergranular corrosion test as per ASTM A 262 (practice A/E).
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. De–greasing : 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 25 μm thick material. Mostly, the composition is as follows; HF
:
5% by mass
HNO3
:
15 to 20 %
Water
:
Remainder
This is followed by rinsing with water. d. Passivation: The surfaces shall be passivated with a solution of the following composition : •
HNO3
:
25% by volume
•
Water
:
Remainder
•
Duration
:
2h
This is followed by rinsing with De-mineralized water.
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
Functional tests of Pressure Regulating System will be demonstrated at site during commissioning of the Facility. The subsystems shall be tested and qualified to the maximum extent possible at the respective manufacturing facilities and will be witnessed by Department’s representative. The integrated system shall be operated and demonstrated at the Department’s site for its capability to meet the requirements specified.
2.6
DOCUMENTATION
The list of documents to be provided by the Contractor at different phases is as follows:
2.6.1 PRELIMINARY DESIGN REVIEW The Contractor shall submit a document listing their comments in the Tender Document provided by the Department. In case the Contractor proposes any alternative scheme, the same with justification along with calculation wherever necessary shall be submitted. In case the Contractor proposes to employ alternative codes/ standards, different from those specified in this document, the copies of such codes/ standards in English shall be submitted.
2.6.2 DETAILED ENGINEERING REVIEW a. Pipe-line lay-out drawings b. Pipe-lines isometric drawings c. Calculations for sizing of Pressure Regulating Valve and actuator d. Design of pipe supports e. Estimation of pressure drop f. Cable lay-out g. QAP h. Procedure and acceptance criteria for fabrication, erection and commissioning i.
Civil and electrical requirements
j.
Purchase specification of materials
k. List of sub-vendors/ sub-Contractors l.
List of spares & source
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
2.6.5 STANDARDS FOLLOWED The Contractor shall follow the following standard for piping, welding, valves etc mentioned in Table 2.5. Table 2.5
: Various st andards/co des fol low ed in PRS Description
Standard/code
Piping
ANSI B 31.3/31.1
SS pipes
ANSI B 36.19
CS pipes
ANSI B 36.10
Butt welded fittings
ANSI B 16.9
Socket welded / threaded fittings
ANSI B 16.11
Flanges
ANSI B 16.5
Stud (fully threaded), Nuts and Washers
ASTM A 193 B8/ B7, A 194 8B/2H
Gaskets
API 601 /ANSI B 16.5/ 16.20/16.21
Ball valves
BS 5351/ API 6-D
Globe/Needle valves
ANSI B 16.34 / API 6-D/API 598/ BS 5352/BS 6755
Pressure regulators
Manufacturer’s standard
Filters
Manufacturer’s standard
43
Non return valves
BS 5352/ API 6-D ASME Section VIII Division I/ API RP 520/
Safety relief valves
API RP 527
Rupture disc device
ASME Section VIII Division 1
Pressure gauges
BS 1780/IS 3624
Hydraulic pressure test of pipelines
ASTM A 530
Pickling & Passivation
ASTM A 380
NDT
ASME Section V
Welding
ASME Section IX, AWS
Radiography
ASTM E 94
Design & Fabrication
ASME Section VIII, division I
2.7
DELIVERABLES
The deliverables for the Pressure Regulation system is given in Table 2.6 Table 2.6
: Lis t of Deliverables
Sr.
Item
no. 1.
2.
3.
4.
Qty.
Pressur e Regulatin g Valve (PRV( 2” ,4” & 12” ))-with actuator,
3
position sensor, servo valve, limit switch , hydraulic piping, etc.
+ 3 nos
Electro Hydraulic Globe Valve(EGV( 2” ,4” & 12” ))- with actuator, solenoid valves, limit switch , hydraulic piping, etc. Manual Ball Valve (MBV ( 2” ,4” & 12” ) ) Hydraulic power pack- with accumulator, hoses, safety devices, etc
3 nos. ( 1 each) 3 nos. ( 1 each) 1 no.
As soci ated pi ping – air piping between EGV4 to air heating 5.
system, hydraulic piping, pipe fittings, pressure relief valve
1 no.
between PRS to air heating system, etc. 6.
Electri cal System- electrical power panels, cabling, switches to operate PRS
Note: The numbers prefixed with ‘+’ are the additional requirement
44
1 no.
MBV2 PRV2
EGV6 4” branch pipe
MBV1
PRV1 MBV3
EGV5 PRV3 EGV 4 (Part of HPS)
Fig. 2.1
EGV7
: Arrangement of PRS with associated valves and piping
45
2” branch pipe
Pressure regulating system
Settling chamber Air heater
Air storage Fig. 2.2
: Pressure Regulating System with adjacent systems 46
Nozzle
Test Section
Fig. 2.3
P & ID of Pressur e Regul ating System
47
48
CHAPTER 3 Air Heating System 3.1 INTRODUCTION Gas based storage heater is proposed for the wind tunnel. Heater bed is contained in the heater vessel, which acts as the heat storage medium. The heater is operated in three cycles i.e. Heating cycle (charge cycle), Blowdown cycle (Discharge cycle) and Reheating cycle (Recharge cycle). In heating cycle, the heater bed is heated to the required temperature by blowing hot combustion gases through the heater bed before the tunnel blowdown (off-line). The combustion gases are produced by burning LPG in the burner placed on top of the heater. In blowdown cycle, the cold air at required pressure and mass flow rate, is sent from bottom of hot bed to top of bed. During this process, the cold air gets heated to required temperature and heater bed loses some of its heat content. In reheating cycle, the hot bed is reheated to required temperature as performed in heating cycle. Thus the heater is operated in these three cycles to simulate the entire tunnel operating
CHAPTER 3 Air Heating System 3.1 INTRODUCTION Gas based storage heater is proposed for the wind tunnel. Heater bed is contained in the heater vessel, which acts as the heat storage medium. The heater is operated in three cycles i.e. Heating cycle (charge cycle), Blowdown cycle (Discharge cycle) and Reheating cycle (Recharge cycle). In heating cycle, the heater bed is heated to the required temperature by blowing hot combustion gases through the heater bed before the tunnel blowdown (off-line). The combustion gases are produced by burning LPG in the burner placed on top of the heater. In blowdown cycle, the cold air at required pressure and mass flow rate, is sent from bottom of hot bed to top of bed. During this process, the cold air gets heated to required temperature and heater bed loses some of its heat content. In reheating cycle, the hot bed is reheated to required temperature as performed in heating cycle. Thus the heater is operated in these three cycles to simulate the entire tunnel operating conditions of Hypersonic Wind Tunnel (HWT) as given in Table 3.1. Schematic diagram of air heating system is shown in Fig. 3.1. Schematic sketch of a typical cored brick storage heater is given in Fig. 3.2.
3.2 MAJ OR WORK DEFINITION The scope of work of Air Heating System (AHS) by Contractor includes design, detailed engineering, fabrication drawings, fabrication, third party inspection, testing, supply of all the systems/ sub systems/ components, installation at site ,commissioning, demonstration of the performance, training and handing over for normal operation. The Air Heating System consists of •
Heater vessel with insulation
•
Heater bed
• Distributor •
Burner-blower for combustion
•
LPG Storage, Handling and Supply System
•
Low pressure air supply and storage system for mixing (diluting) air
•
Chimney with Interface pipe lines
•
Vent pipe lines
•
High pressure and High temperature valves (hot Shut-off valves) with associated pipe lines
•
Pipeline between PRS to heater & downstream of heater to connect to settling chamber 49
•
Expansion bellows to absorb thermal expansion
•
Foundations and Supporting structures for heater, all valves and all pipe lines
•
Safety devices
•
Instrumentation and control for operating air heating system
•
LPG leak detection system
•
Smoke and flame detector
•
Pressure sensors
•
Temperature sensors along with thermo-well
•
Flow measurements
•
Electrical System
The details of Contractor’s scope of work shall include the following. •
Design of all the subsystems/ components of Air Heating System (AHS).
•
Transient thermal analysis, thermo structural analysis for heater, piping etc.
•
Detailed engineering of the system and generation of purchase specifications.
•
Purchase of all materials such as equipments, flow components, instruments, pipes, pipe fittings, etc.
•
Fabrication, testing and co-ordination for inspection of the system at the Contractor’s factory.
•
Transportation of materials to and storage at the Department’s site.
•
Erection, testing and co-ordination for inspection of the entire system at the Department’s site.
•
Commissioning of AHS.
•
Demonstration of the performance, training and handing over to the Department.
50
Fig. 3.1
Schematic of Air Heating syst em
51
C
H
D
Fig. 3.2
Ds – Shell o uter d ia. Di- Shell Inner di a. Db- Bed di a. H – Heater heigh t h- Bed height
Typical sketch of cored bric k Storage heater
3.3 TECHNICAL SPECIFICATION 3.3.1 HEATER BED The Hypersonic Wind Tunnel Facility will be operated at different pressures, temperatures and mass flow rates. Therefore, the heater shall cater to the requirements of all tunnel operating conditions. The pressures, temperatures and mass flow rates to be simulated are given in Table 3.1. Two heaters are required to meet the entire operating conditions. Heater 1 can handle maximum mass flow rate of 180 kg/sec at 700K. Heater 2 can deliver a maximum mass flow rate of 60.6 kg/sec and can handle maximum temperature upto 1700 K. Any one of the heaters will be used at a given time depending on the test requirement. Input conditions for design are given in Table 3.2. The heater bed should be designed in such a way that the outlet temperature of air varies within + 50 K during the tunnel blowdown (40 seconds minimum). The heater bed will be made of cored brick. The heater bed shall be designed to maintain a thermal gradient towards the bottom layer of the bed. 52
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
Different operating condit ions for Air Heating System Heater 1 Heater
Operating
Stagnation
Stagnation
Mach
Pressure
Temperature
number
(bar)
(K)
1
5L
10
346
446
61.38
2
5
20
364
464
119.55
3
5H
30
376
476
180
4
6.5 L
10
487
637
16.57
5
6.5
20
510
660
32.38
6
6.5
30
525
675
47.87
7
6.5
40
536
686
63.17
8
6.5
50
545
695
78.31
9
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)*
Mass flow r ate (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
8
20
682
932
12.80
16
8
30
700
950
18.94
17
8
40
714
964
25.02
Sl. No.
53
18
8
50
725
975
31.04
19
8
60
734
984
37.02
20
8
70
742
992
42.96
21
8
80
749
999
48.86
22
8
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
Design input condit ions for air heating syst ems Parameter
no.
Heater-1
Heater2
1
Operation of Heater
Intermittent
Intermittent
2
Fuel
LPG
LPG
3
Inlet temperature of air
200 - 300 K
200-300 K
4
Outlet temperature of air
700 + 50 K
1700 + 50 K
5
Maximum working pressure
13 MPa
13 MPa
6
Maximum pressure drop per 10 KPa
10 Kpa
unit height of heater bed 7
Maximum mass flow rate
180 kg/sec
60.6 kg/sec
8
Maximum Shell temperature
333 K
333 K
10
Life of heater bed
10,000 cycles
10,000 cycles
11
Charging time
8h
8h
12
Recharging time
2h
2h
13
Blowdown time (minimum)
40 s
40 s
15
Heater vessel design
ASME
code
and ASME
relevant standards
code
and
relevant standards
3.3.2 THERMAL INSULATION OF HEATER Liner bricks shall be provided between the cored brick bed and the heater vessel to limit the inner wall temperature of the heater vessel to 333 K . The liner bricks shall be designed to meet this requirement. The liner bricks also should have the same quality as that of heater bed material with respect the thermal shock and abrasive resistance.
3.3.3 HEATER VESSEL Design pressure
: 13MPa
Design temperature
: 333 K
Design code
: ASME Boiler and Pressure Vessel Code.
Material
: SA 516 Grade 70 or equivalent material
The liner bricks and heater vessel integrity shall be ensured by the Contractor.
55
3.3.4 MAN HOLES Top and bottom dome of heater should be manufactured as a separate unit which can be detachable to facilitate maintenance. Suitable flanged joint will be provided as shown in Fig. 3.1. A man hole will be provided at the bottom of the shell.
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.
3.3.7 VENT PIPES A pipe of inside diameter 8” (tentative) shall be provided on the top of heater to vent out the trapped mass of air inside the heater. The venting pipe shall be designed for a pressure of 13 MPa. Overnight losses from the bed would result in a thermal gradient with a maximum
temperature at the middle of the bed and lower temperatures at the top due to radiation losses from the bed to the chamber walls. Air is required to be passed from the bottom to the top of the bed (at the start of each day) to modify the thermal gradient across the bed height and to ensure that the peak temperature is at the top of the bed. This air will be vented out through this pipe. A suitable thermal insulation shall be provided for this pipe to take care of the high temperature environment. High pressure and high temperature valves shall be provided for opening & closing of the vent pipe.
The Combustion gas and
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
LPG STORAGE, HANDLING AND SUPPLY SYSTEM
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
LPG UNLOADING SYSTEM
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
LPG STORAGE SYSTEM
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
PRESSURE REGULATING DEVICE
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
SPRINKLER AND FIRE FIGHTING SYSTEM
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
LPG AND WATER PIPING
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 electronic instruments and 5
Ω
Ω for
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
a) Remotely Operated Valves (ROV’s) at strategic locations. b) Level transmitter with high-level set point; i.e. 80% of safe filling limit. c) Magnetic liquid level gauge with dial indication. d) Overfill protection device interconnected with starter of pumps and compressors when 80% of safe filling limit is achieved. e) Excess flow valve on all inlet and outlet lines from the vessels. 10. Bottom of tank should have outlet with Remotely Operated Valve. Installation of high temperature and high pressure alarm with auto-activation of water sprinklers need to be installed. Side discharge type safety relief valve should be used. 11. The entire fenced area of the LPG/Propane Bulk Storage Yard shall be covered with leak detection sensors in general and sensors shall be located at areas prone to fire risk / leakages in particular. When sensors are activated as per pre -determined setpoints, they activate the necessary audio-visual alarm and also the Medium Velocity Water Spray Sprinkler (MVWSS) system. 12. Necessary device to be installed at Control Room, which can locate the area of leakage zone preciously for taking necessary emergency action. 13. The Control Room shall be able to precisely identify the affected zone as the location of activated sensor is mimicked on the Control Panel. 14. Remotely Operated Valves (ROV’s) are to be provided at strategic points on the gas pipeline circuit and on the feeder lines of the MVWSS system. 15. These ROV’s shall be interlocked for auto-activation in the event of an emergency and should also be activated by the emergency shutdown station. 16. The MVWSS system should be also provided in the tanker unloading bays
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.
3.3.11 HOT SHUT-OFF VALVES
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
: Schematic of High press ure and High temperatu re valves
62
Table 3.3
Specifi cations of Hot shuto ff valves Specifications of Hot shut valves
Application End connection Permissible leak rate Flow direction Min. operation Life Safety
Isolation (hot air) Flanged as per ANSI B 16.5 Class VI as per ANSI standard/ Bubble t ight as per API 598 Flow to open 10000 cycle Fail to close
Heater-1 HSV1 300
Size(mm)
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
Valve position Tempreture Pressure Valve position Tempreture (Flow) Response time Pressure(MAWP)
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 HSV3 300
Size(mm)
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
Valve position Tempreture Pressure Valve position Tempreture(Flow) Response time Pressure(MAWP)
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
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
63
3.3.12.1 VALVE SPECIFICATIONS HSV shall comprise the actuator, suitable solenoid valve and limit switches. Application
:
Isolation (hot air)
Size
:
DN 300 or burner size
End connection
:
Flanged/Welded end as per ANSI B 16.5
Cycle of operation
:
10,000 cycles
Flow direction
:
Flow to open
Permissible leak rate
:
Class VI as per ANSI B 16.34 Bubble tight as per API 598
Actuation
:
Solenoid & limit switches redundancy:
Electro pneumatically operated Level three
ACTUATOR Safety
Fail to close
3.3.12.1 VALVE SPECIFICATIONS HSV shall comprise the actuator, suitable solenoid valve and limit switches. Application
:
Isolation (hot air)
Size
:
DN 300 or burner size
End connection
:
Flanged/Welded end as per ANSI B 16.5
Cycle of operation
:
10,000 cycles
Flow direction
:
Flow to open
Permissible leak rate
:
Class VI as per ANSI B 16.34 Bubble tight as per API 598
Actuation
:
Solenoid & limit switches redundancy:
Electro pneumatically operated Level three
ACTUATOR Safety
:
Fail to close
Command fluid
:
Air / Hydraulic
Redundancy
:
Level three
3.3.12.2 ASSOCIATED PIPELINES (Ref. Fig 3.3 & Table 3.4) Table 3.4 Sr. No. 1 2
3
Pipeline
Assoc iated piping for Air heating system piping Nominal
Ap pr ox im ate
Working
Working
Pipe si ze
Length
pressure
Temperature
(m)
(MPa)
(K)
25
13
TBD#
18
13
700
5
13
1700
12”
35
0.6
1700
PRV to heater
12”
Heater1 to Settling
12”
chamber Heater2 to Settling
12”
chamber
4
Heater to chimney
5
Heater1 to vent
8”
4
13
TBD
6
Heater2 to vent
8”
4
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.
3.3.12.3 EXPANSION JOINTS FOR PIPE LINES The Expansion joints are to be designed and supplied by Contractor for pipe lines where thermal stresses are to be relieved. Tentative locations are shown in Fig. 3.3. The working conditions of pipelines are given in Table 3.4.
3.3.12 COOLING SYSTEM Upper part of heater shell where temperature is maximum and the parts between the flange joints of heater shell and burner assembly may be required to be cooled. The high pressure and high temperature valves are subjected to very high thermal stresses. Therefore components of valves need to be water cooled. The Contractor shall work out required cooling water pressure and flow rate and supply the cooling system.
3.3.13 FOUNDATIONS A ND SUPPORTING STRUCTURES FOR HEATER, A LL VALVES AND ALL PIPE LINES Civil works will be carried out by the Department. Therefore, Contractor has to provide all necessary foundation details.
3.3.14 SAFETY DEVICES Pressure relief devices are to be provided and routed outside building in air heating system at suitable places to protect the system from being exposed to high pressure. Necessary safety devices like thermal overload protection switches to protect the electric motors from drawing excessive current, pressure switches in the pneumatic and LPG lines, proximity switches for isolation valves, etc will be provided. These devices must meet national and internal standards.
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3.3.15 INSTRUMENTATION AND CONTROL OF AIR HEATING SYSTEM The instrumentation & control system of air heating system should be catered for storage & handling of LPG, controlling of LPG supply, controlling of burner-blower system, operating of hot shut off valves (HSV), Controlling & maintaining of heater temperature etc. LPG storage & handling system is responsible for handling of LPG as per OISD norms. This system may make use of pressure sensors, temperature sensors, LPG leakage detectors, smoke & flame detectors, water sprinkler systems, fire fighting systems, remotely operated valves etc. This system needs to work round the clock. LPG supply controller is responsible for supplying of LPG at pre-defined rate. This system may make use of pressure regulating valves, pressure sensors, flow rate sensors etc. Burner-blower controller is responsible for supplying the pre-set air-fuel ratio, burning the fuel at pre defined rate, maintaining the constant combustion pressure in the heater shell. Heater temperature controller is responsible for maintaining the desired temperature profile in the heater during charging, recharging and blow down cycle.
A dedicated instrumentation & control system is to be provided for exclusive operation of AHS.
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, do’s & don’ts 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. RTD’s are to be
67
provided for grate temperature measurement. Total 10 temperature measurements are planned on each heater. Exact locations will be decided based on mutual discussions. 2. Ai r Temperat ur e Measu rement : It is to be performed during charge/recharge and blow down cycle. During charge/recharge cycle, combustion air temperature is measured. While in blow down cycle, blowdown air temperature is measured. 3. Vessel Pressure Measurement: It is to be performed during charge/recharge and blow down cycle. During charge/recharge cycle, combustion air pressure is measured. While in blowdown cycle, blowdown air pressure is measured. Due to large variation in the operating pressure during charge/recharge cycle and blow down cycle, multiple ranges of pressure sensors are needed. Safety interlock is provided in selecting suitable range of sensor while in the type of heater operation (i.e. charge/recharge, blow down cycle). 4. Outer shell s urface temperature: Hand held radiation pyrometer is to be provided for measuring outer shell surface temperature. This is essential for ensuring the shell temperature within the safety limits.
3.3.17 SCOPE OF WORK The scope of work consists of the following:
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 (i)
FABRICATION
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)
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 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.
3.3.17.4 INSPECTION AND TESTING I.
Inspection and testing requirements, acceptance standards shall be identified at different stages of realization of the system through process and QC plan. Critical stages of realization will be identified in the process/QC plan right from raw material qualification to the final stage of the system and also erection and commissioning. Fabrication process and QC plan will be approved by the Department before initiation 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, manufacture’s serial number, date of inspection and inspector’s stamp shall be marked.
IX.
It shall be the Contractor’s 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
Insulation Bricks and cored bricks
10 % of installed qty.
2
Burner
2 no.
3
High pressure and High temperature valve
2 no.
4
All ‘O’ rings
2 sets
5
All Gaskets
2 sets
6
All fasteners with washers
10 % of installed qty.
7
Critical parts (to be listed by Contractor)
10 % of installed qty.
3.3.18 ACCEPTANCE TESTS: After installing air heating system at site, the Contractor shall carry out functional tests of all subsystems of AHS to meet their specifications.
The Contractor shall carry out charge
cycles, blowdown cycles and recharge cycles to simulate tunnel operating conditions for Mach numbers of 5, 6.5, 8, 10 and 12 as given in Table 3.1. These tests shall be repeated by Contractor to ascertain consistency. The Contractor should demonstrate a good comparison between achieved temperature profiles of heater bed and blowdown air with theoretical temperature profiles for charging and recharging phases.
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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. -
Overall documentation of AHS with technical details.
-
Mass of Air Heater
-
Size, number and type of beds.
-
Burner specifications
-
Overall size of shell
-
Wall thickness of pressure vessels refractory and insulation linings
-
Mechanical properties and chemical compositions of materials of AHS.
-
Technical deviation, if any should be highlighted.
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 Department’s approval shall not absolve the Contractor’s 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
XI. Prior to delivery of the consignment: On completion of fabrication, but at least 2 weeks before the expected date of delivery of the consignment, the following documents shall be sent to the Department. The Department will review the same to ensure compliance with the specification of the purchase order. On being satisfied, the Department will issue a “dispatch clearance”. a. The certificates of all tests shall be provided. Each page of the certificates shall be duly counter-signed and stamped by the TPI agency. b. Pre-delivery inspection certificate by the TPIA. c. As-built GA drawings d. Instruction manual for erection, commissioning, operation, trouble shooting and maintenance.
3.3.20 INTEGRATION AND COMMISSIONING I. The sub-systems/systems realized and qualified at stage level, shall be integrated as laid out in the document II. The Contractor shall work out the detailed plan for integrating the systems realized by them. Facilities/equipments/infrastructure needed for the task shall be totally taken care by them. The electrical power requirements shall be informed to the Department and the same shall be provided on chargeable basis III. The Contractor shall carry out Functional tests and Acceptance tests, in the integrated condition, ensuring the performance of all systems to the specified requirements IV. In the event of not meeting specified requirements by any of the systems realized by them, the same shall be attended to and necessary modifications shall be carried out to make it operational in all respect.
3.4 DELIVERAB LES The list of deliverables is given below in Table 3.5. Table 3.5: List of deliverables Sr. no. 1
Item
Qty.
Heaters- with heater vessel, cored brick bed, insulation, distributor plates, flue gas analyzer, safety valves etc. Hot Shut off isolation Valve (HSV)- High temperature
2
2 nos. (1 each) 8 nos.
high pressure valves with actuator, limit switch , hydraulic
+ 2 nos (HSV2
piping, etc.
HSV4- 1 each). 73
Burner Syst em- with burners, blowers, flow control 3
valves, sensors, safety devices(smoke detector, LPG
2 nos.
detector) 4
Hydraulic pow er pack for HSV- with accumulator, hoses, safety devices, etc.
1 no.
As so ci ated pi ping – High pressure- high temperature air 5
piping upto settling chamber, hydraulic piping, cooling water piping, vents, LPG piping, pipe fittings, pressure
1 no.
relief valves, etc. LPG System- LPG bulk storage system with 2 nos. of storage vessel 60 MT capacity each, LPG unloading 6
system, LPG feeding system, Sprinkler system, LPG leak
1 no.
detectors, flame detectors, fire fighting system and associated piping as per OISD guidelines, 7 8
9
10
Chimney- Chimney with associated piping Standalone Contr ol System- with associated cabling and sensors Ad di ti on al s ensor s- radiation thermometer, thermal image camera, smoke and flame detector etc, Electri cal System- electrical power panels, cabling, switches to operate PRS
TBD – To be decided
74
1no. 1no.
TBD
1no.
CHAPTER 4 Tunnel System 4.0 INTRODUCTION Tunnel system is the most important part of the whole hypersonic wind tunnel. Successful testing is possible only when this system performs efficiently. Tunnel system consists of following subsystems. 1. Settling chamber 2. Nozzles 3. Test section/ plenum chamber 4. Model incidence mechanism 5. Diffuser system 6. Connecting duct 7. After cooler Fig 4.1 shows the schematic diagram of this total system. Tunnel system is connected to Air heater on the upstream and vacuum system on downstream side.
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
Fig. 4.1 Block diagram of Wind tunnel system 4.1 SETTLING CHAMBER 4.1.1 INTRODUCTION: Settling Chamber is a large area low velocity section connected to a pipeline in the upstream and in downstream it is connected to the nozzle. It is needed to improve the uniformity of the flow entering the nozzle. The supply pressure of the high pressure tank reduces during the run and thus the flow in these tanks and lead-in pipes becomes highly turbulent. In addition, as the valve is opened to initiate the test, it introduces additional unsteadiness. The settling chamber is used to reduce this turbulence in the flow before it enters the nozzle. Settling Chamber consists of conical section called wide angle diffuser in upstream side followed by a cylindrical portion with flow manipulators.
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.
4.1.2 SYSTEM CONFIGURATION Two settling chambers are required to meet the entire operating conditions of the tunnel. The schematic diagram of settling chambers with flow manipulators and support structure is shown in Fig. 4.2.
Nozzles
a. Settling chamber 1 (SC 1) 76
b. Fig. 4.2
Settling chamber 2 (SC 2)
Schematic of the settling chambers with flow manipulators and support str ucture
The settling chamber consists of •
Wide angle diffuser
•
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.
4.1.3 TECHNICAL SPECIFICATION Quantity
:
2 no.
Inlet (interface to pipeline)
:
12” flange (for SC1 & SC 2)
Outlet diameter**
:
600 mm (for SC 1)
:
300 mm (for SC 2)
:
5965 mm (Approximate)
Overall length
77
Design pressure+
Operating flow temperature
Mass flow rate (max)
Design code
:
13 Mpa for SC 1
:
13 MPa for SC 2
:
700 K± 50K for SC 1
:
1400 K ± 50K for SC 2
:
180 kg/sec (for SC 1)
:
60.6 kg/sec (for SC 2)
:
ASME code for fired pressure vessels Section – VIII, Division 1
Material of construction
For SC1 (tentativ e)
Shell
:
SA 516 Gr. 70
Flow manipulator
:
ASTM A 240 SS 321
Insulation liner
:
ASTM A 240 SS 321
Material of construction
For SC2 (tentativ e)
Shell
:
SA 516 Gr. 70
Flow manipulator
:
INCONEL 718/Haynes-214
Insulation liner
:
INCONEL 718/Haynes 214
**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 Poros ity : 63.25 %
PP2 Hole dia. Pitch No. of hol es Porosi ty
: : : :
20 mm 25 mm 451 50.11%
PP3 Hole dia. : 10 mm Pitch : 15 mm No. of hol es : 1303 Porosi ty : 36.19%
PP4 Hole dia. Pitch No. of hol es Porosi ty
: : : :
5 mm 9 mm 3619 25.13%
EXIT
IN
Fig. 4.3 Schematic of th e SC 1 with f low manipulator details 79
PP1 Hole dia. : 30 mm Pitch : 33.7 mm No. of holes : 61 Porosi ty : 61%
Hole dia. Pitch No. of holes Porosi ty
PP2 : 20 mm : 24 mm : 121 : 53.78%
THERMAL INSULATION Hole dia. Pitch No. of hol es Porosi ty
PP3 : 10 mm : 15 mm : 313 : 34.78%
Hole dia. Pitch No. of holes Porosi ty
PP4 : 5 mm : 9 mm : 883 : 24.53%
EXIT
PP1 Hole dia. : 30 mm Pitch : 33.7 mm No. of holes : 61 Porosi ty : 61%
Hole dia. Pitch No. of holes Porosi ty
THERMAL INSULATION Hole dia. Pitch No. of hol es Porosi ty
PP3 : 10 mm : 15 mm : 313 : 34.78%
Hole dia. Pitch No. of holes Porosi ty
PP2 : 20 mm : 24 mm : 121 : 53.78%
PP4 : 5 mm : 9 mm : 883 : 24.53%
EXIT IN
Fig. 4.4
Schematic of the SC 2 with flow manipulator detail
80
4.1.3.1 MECHANICAL DESIGN Mechanical design of the settling chamber includes the shell design, the type of joints, assembling and fixity of the thermal insulation/liner and the flow manipulators. The interface of settling chamber shall be from the flange of heater end piping. Note: Tentative materials have been quoted for different components only for reference purpose. Contractor will carry out detailed thermo structural analysis to finalize the material.
4.1.3.2 THERMAL INSULATION Both the settling chambers will 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 Contractor shall design, fabricate and integrate the thermal insulation with the settling chambers. The Contractor
4.1.3.1 MECHANICAL DESIGN Mechanical design of the settling chamber includes the shell design, the type of joints, assembling and fixity of the thermal insulation/liner and the flow manipulators. The interface of settling chamber shall be from the flange of heater end piping. Note: Tentative materials have been quoted for different components only for reference purpose. Contractor will carry out detailed thermo structural analysis to finalize the material.
4.1.3.2 THERMAL INSULATION Both the settling chambers will 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 Contractor shall design, fabricate and integrate the thermal insulation with the settling chambers. The Contractor shall ensure the integrity of the thermal insulation for 10,000 cycles of operation. The tentative material for the thermal insulation is ASTM A240 SS 321 and INCONEL 718/Haynes-214 for settling chamber 1 and 2 respectively.
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.
4.1.3.5 FLOW MANIPULA TORS The flow manipulators shall be designed as per the details as given in Fig. 4.3 and Fig. 4.4. Provision is to be kept to incorporate additional manipulator for future augmentation (if required). The thickness of the flow manipulator shall be designed by Contractor to withstand the design pressure and temperature as per ASME code. Suitable materials for flow manipulator shall be selected by Contractor to suit the operating conditions of the settling chambers. Tentative material of flow manipulator is ASTM A 240 SS 321 or its equivalent for SC 1 and INCONEL 718 for SC 2. However, the Contractor will carry out detailed thermo structural analysis considering mechanical and thermal load and finalize suitable material. Adequate arrangement shall be provided for holding the flow manipulator against operational loads, thermal expansion and also it should be removable for ease of maintenance.
4.1.3.6
SUPPORT STRUCTURE
The settling chamber will be mounted on support structures. Each segment shall be provided with separate support structure. The support structures will be movable on rails that are provided on the building floor. A suitable rolling system with locking mechanism shall be provided for the movement of the settling chamber in both axial and lateral direction. This centerline of the settling chamber is fixed at a height of 1.5m from the building floor. A suitable height adjusting mechanism shall be provided on the support structure to take care of a height adjustment of ±50 mm. Support structure shall be made out of structural steel. The lateral wheel shall have vertical movement capabilities with suitable mechanism/actuator to lift total settling chamber assembly at least 100 mm for lateral movement of settling chamber.
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4.1.3.7 MEASUREMENTS PORTS Each settling chamber shall be provided with 8 Nos. of measurement ports for pressure and temperature measurement. For pressure measurement, suitable adaptor shall be provided for nullifying the temperature effect (i.e., reduction from stagnation temperature to ambient temperature). Tentative size of nozzle is 2” & the locations of nozzle are shown in Fig. 4.2. The exact size and location will be finalized based on mutual discussion.
4.1.4 ACCEPTANCE TEST Hydrostatic t est and vacuum leak rate test Hydrostatic test will be carried out as per standard. Vacuum leak test will also carried out to ascertain an allowable leak rate of 10 -8 Pa-m3/sec. These tests will be carried out at the Contractor’s site during inspection.
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.
4.2.2 SYSTEM CONFIGURATION The nozzle consists of •
Convergent region
•
Throat region
•
Cooling system for throat region( For Mach 8,10 & 12 Nozzles only)
•
Divergent region
•
Interface with the Test Section
•
Interface with the Settling Chamber
•
Support trolley structure with wheels
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
1
Ø600
2
4
3
5
7
6
8
Ø1000 Ø 1700
see detail E see detail E
see detail E
see detail E
see detail E
M5
30 80 Detail E
727
500
1
Ø600
800
2
800
1000
4
3
1000
5
1200
973
7
6
8
Ø1000 Ø 1700
see detail D see detail D
see detail D
see detail D
see detail D
M6.5
30 80 see detail D
650
500
800
800
1000
1000
1200
1050
6
7
8
cooling circuit
Ø300
1
2
3
4
5
see detail C see detail C
see detail C
M8
see detail C
30 80 Detail C
85
Ø1099
Ø1700
500
500
800
800
1000
1000
1200
1200
cooling circuit
Ø300
1
2
4
3
6
5
7
Ø1150 Ø1700
8
see detail B see detail B
see detail B
see detail B
see detail B
M10 80
30 Detail B
750
800
800
1000
1000
1200
5
6
1450
Water cooled throat
1
3
2
4
Ø1213 Ø1700
7
see detail A see detail A
see detail A
see detail A
see detail A
M12 80
30 Detail A
Fig. 4.6
Diagram of the nozzle assembly for indivi dual Mach numbers
4.2.3Technical Specifi cation s 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 and operating condit ions of the nozzles
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
Stagnation Pressure, MPa
3.0
10
10
10
10
Flow Temperature, K
400
600
800
1100
1400
4.2.3.1 MATERIAL Table 4.2
: Tentative lis t of materials Segments
Mach No.
5.0 6.5
8.0
10.0
12.0
1
2
AISI
AISI
304L
304L
AISI 304L
4
5
6
7
8
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
*Nozzle throat section The tentative material list for the different segments of the nozzle is given in Table4.2. However, Contractor will finalize the material based on detailed thermo-structural analysis
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 Φ1mm 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.
4.2.3.3 FAB RICATION TOLERANCE The allowable tolerances on the machined inside surface are i. ±0.02 mm in the throat segment on diameter ii. ±0.06 mm in other places on diameter •
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.
•
The nozzle shall be reinforced by stiffeners along the external circumference to maintain the contour, during machining and handling only.
88
4.2.3.4 SURFACE FINISH The Contractor shall ensure internal surface finish of N6 (0.8 μm).
4.2.3.5 COOLING SYSTEM The throat segment of Mach 8, Mach 10 & Mach 12 nozzle assembly needs to be cooled externally to withstand high temperature. The Contractor shall carry out the cooling system design, detailed engineering, cooling water pumping requirements, fabrication and integration of the cooling system with nozzle and supply. The pumping required for cooling system shall be supplied by the Contractor along with the nozzle assemblies. Provision for mounting one temperature sensor at outlet and two pressure sensors at inlet & outlet shall be provided.
4.2.3.6 MEASUREMENT PORTS Provision for mounting pressure sensors at the nozzle exit with suitable adaptor shall be provided. The adaptor shall take care of nullifying the t emperature effect.
4.2.3.7 SUPPORT STRUCTURE The nozzle assembly will be mounted on support structures. The support structures will be movable on rails, which are provided on the tunnel floor. A suitable rolling system with locking mechanism shall be provided in the support structure for the movement of the nozzle assembly in both axial and lateral directions. The centerline of the nozzle assembly is fixed at a height of 1.5 m from the building floor. A suitable height adjusting mechanism shall be provided on the support structure to take care of a height variation of ±50 mm. Support structure shall be made out of structural steel. The lateral wheel shall have vertical movement capabilities with suitable mechanism/actuator to lift total nozzle assembly at least 100 mm for lateral movement of Nozzle. . 4.2.4
ACCEPTANCE TEST - HYDROSTATIC TESTING & VACCUM LEA K TEST
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.
4.3.2 SYSTEM CONFIGURATION The Test Section consists of • Compartment – I
— Interface with nozzle assembly — Interface with scoop assembly and supersonic diffuser — Doors • Compartment - II
The model incidence mechanism is accommodated in the compartment - II. The nozzle assembly and supersonic diffuser are interfaced with the compartment - I of test section with flanged joint and the flow takes place through the compartment -1. Schematic of test section with model incidence mechanism is shown in Fig. 4.7.
90
SCOOP ASSEMBLY
DOOR
NOZZLE
COMPARTMENT-1
SCOOP
SUPERSONIC DIFFUSER
PITCH MECHANISM
AXIAL MECHANISM
INJECTION MECHANISM
COMPARTMENT-11
Fig. 4.7
: Schematic of Test section with Model incid ence mechanism
4.3.3 TECHNICAL SPECIFICATION The detailed mechanical design of the Test Section shall be carried out by the Contractor. The tentative details of the test section components are described below:
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:
a. INTERFACE WITH NOZZLE The nozzle is rigidly mounted with the test section wall with a flanged joint. The nozzle assembly shall be protruding approximately 1300 mm into the compartment - I. The tunnel is housed in the first floor of the tunnel building and tunnel centerline is 1.5m from the floor. The nozzle shall be integrated with the test section within the concentricity of ø1 mm. The nozzle test section interface shall be leak proof both at high pressure (0.2 MPa) and vacuum of 0.01 mbar. The interface shall be designed for easy assembly & dismantling of 91
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.
b. INTERFACE WITH SCOOP ASSEMBLY AND SUPERSONIC DIFFUSER The supersonic diffuser is rigidly mounted with the test section wall in the downstream end maintaining the tunnel centreline (1.5m from the floor). The supersonic diffuser shall be integrated with the test section within the concentricity of ø1 mm. The upstream end of the diffuser known as scoop assembly is a convergent duct followed by a straight duct. The straight portion of the scoop slides into the straight portion of the supersonic diffuser. The distance between the nozzle exit and the scoop entry is variable between 0.8m and 2.8m. A cut out of size 1.3m length and 0.5m wide is to be provided at the start of scoop for Model Incidence Mechanism operation. The Contractor shall design the interfacing of the scoop assembly in the test section with a provision for axial movement of 2m. The Contractor shall design and supply a suitable traversing mechanism for the movement of scoop. The supersonic diffuser – test section interface shall be leak proof both at high pressure and vacuum and necessary sealing shall be provided. The Contractor shall design the interface taking into account the dimensions of the supersonic diffuser and scoop. The interface shall be designed for easy assembly. The diffuser and scoop shall be integrated with the test section within the concentricity of ø1mm.
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.
d. CUT-OUT FOR MODEL INCIDENCE MECHANISM: The compartment - I shall be isolated from the compartment - II by steel platform. A cut-out of size 3.5m (L) x 1.1m (W) shall be provided on the platform. Sliding door shall be provided to open and close the cut-out with suitable mechanism (hydraulic / electro mechanical). The platform shall be of removable type for the maintenance of Model Incidence Mechanism.
e. TOP COVER OF THE COMPARTMENT – I : The top cover of the compartment –I should be designed as a removable member to facilitate assembly of diffuser. It is also necessary for any future augmentation of incorporating a top chamber for rapid injection mechanism. A flange shall be provided on the top of compartment - I for mounting ∅700 mm glass window which is necessary for Advanced Measurement like Pressure Sensitive Paint (PSP) technique, Laser based diagnostics (PLIF/PIV). 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.
4.3.3.3 DESIGN INPUTS: The test section (all the compartments) shall be designed as per ASME code for an operating internal pressure of 0.2 MPa. The design should be also checked for external atmospheric pressure for internal vacuum condition. The proposed material is SA 516 grade 70 or its equivalent.
4.3.3.4 PORTS FOR INSTRUMENTATION CAB LES AND COOLING SYSTEM HOSES A number of ports shall be provided in the test section for routing instrumentation cables, hydraulic and cooling system hoses. Proper feed through must be provided to avoid 93
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.
4.3.3.5 MEASUREMENT PORTS Provision
shall
be
provided
for
mounting
the
sensors
for
performing
following
measurements. •
Test Section pressure
•
Test Section temperature
•
Test section vacuum level
4.3.3.6 DOOR OPERATION All the doors provided in the test section shall be operated remotely from the tunnel main control room. However, a control panel with manual overrides shall also be provided for door operation near the test section for opening / closing of doors during the preparation for blowdown.
4.3.4 ACCEPTANCE TESTS The Test Section shall be pneumatically tested for internal pressure as per standrad and vacuum at 0.01 mbar at Contractor’s site during inspection. For vacuum, the allowable leak rate shall be less than 10 -8 Pa m3/s.
4.4 MODEL INCIDENCE MECHANISM (MIM) 4.4.1 INTRODUCTION Model Incidence Mechanism (MIM) has to perform two functions: a. to support the model rigidly against the aerodynamic loads acting on the model and the mechanisms. b. to inject the model into the flow after flow stabilization in the tunnel and orient the model with respect to the flow direction. The MIM shall provide pitch, yaw and roll motions to the model during test in the injected position. It should retract the model after t he test.
The model incidence mechanism has five degrees of freedom: — vertical movement for injecting the model into the flow; — linear horizontal movement along the tunnel axis; 94
— three angular movements for changing the orientation of the model with respect to the flow axis (Pitch - α, Yaw - β and Roll - φ). 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).
4.4.2 SYSTEM CONFIGURATION Schematic of MIM is shown in Fig. 4.8 Roll mechanism Pitch mechanism
Yaw mechanism
Horizontal mechanism
Vertical mechanism (for injection)
Fig. 4.8
Schematic of Model Incidence Mechanism
Schematic of Model Incidence Mechanism in the test section at different positions is shown in Fig. 4.9.
95
a) MIM in Compartment – II
b) MIM in Compartment – I at α = 0º
(before injection)
(after injection)
c) MIM in Compartment – I at α = 45º
d) MIM in Compartment – I at α = -10
Fig. 4.9 Schematic of t he proposed Model incidence mechanism in different positions in Test section
96
4.4.3 TECHNICAL SPECIFICATIONS The technical specifications of model injection mechanism are given below in Table 4.3. Table 4.3
Technical specifications for model incid ence mechanism
Sl no
Parameter
Specific ations
1.
Quantity, Nos.
1 1.75 m approx.
2.
Injection distance
(vertical distance traveled by MIM from compartment-II to the tunnel axis) Conventional Mechanism < 2 sec
3.
Injection time
Rapid Injection Mechanism ~200 msec (Only in flow jet around 610mm)
4.
Injection drive
Hydraulic/ Electric
5.
Pitch range
-10° to +45°
6.
Pitch drive
Servomotor with a worm and worm gear
7.
Pitch rate
1°/sec to 15°/s at variable rates
8.
Yaw range
-10° to +10°
9.
Yaw drive
Servomotor with a worm and worm gear
10.
Yaw rate
1°/sec to 15°/s at variable rates
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.
Axial movement rate
~ 5 mm/s
17.
Mode of operation (pitch/yaw/roll)
Both continuous and pause mode
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 syst em, 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
Note - These loads are likely to change The leading edge of the strut of model incidence mechanism, which is inside the flow, shall be a wedge with a semi vertex angle of 15º. iii. Blockage: The blockage of the model incidence mechanism along with sting in any case shall not exceed 5% iv. Mechanical design: The system shall be designed for the aerodynamic loads mentioned above with a factor of safety of 3 on yield stress. Suitable materials should be selected. Tip of the strut which is subjected to repeated thermal environment can be made replaceable. The design shall be checked for the stiffness and vibrations. The maximum deflections permitted on the model at any orientation of the model with reference to model centre of rotation is 0.1º. v. Thermo-structural analysis: The Contractor shall carryout detailed thermo-structural analysis to finalize the material. However, a tentative list of material is given for reference. a.
15-5 PH shall be used for strut, model mounting pod.
b.
SA 240 Gr 304L for other parts of the model incidence mechanism.
c.
Maraging steel for sting.
d.
Niobium for tip of model strut
98
4.4.3.2
CONTROL
All the operations will be pre-programmed 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 ‘α’, ‘β’ and ‘φ’ in the main control console computer. A control panel with manual override shall be provided near the tunnel test section.
4.4.3.3
INTEGRATION WITH TEST SECTION
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.
4.4.4 ACCEPTANCE TESTS The Contractor shall carryout the functional tests of the mechanism as per specifications during commissioning of the wind tunnel at site. Mutually agreed Acceptance test plan will be worked out before commissioning commissioning the system
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 The diffuser consists of •
Scoop assembly
•
Scoop Mechanism for axial movement
•
Supersonic diffuser (constant area duct)
•
Subsonic diffuser
•
Interfacing of the scoop mechanism in the test section
•
Interfacing of the supersonic diffuser to the test section 99
•
Interfacing of the subsonic diffuser to the connecting duct
•
Interfacing of the vacuum isolation valve to supersonic and subsonic diffusers.
Entire diffuser assembly shall be supported on rails. Schematic of the outline of the diffuser is shown in Fig 4.10. 4.10.
Scoop
Constant area duct
Subsonic diffuser
Fig. 4.1 4.10 0 Schematic Schematic o f the out line of th e diffuser
4.5.3 TECHNICAL SPECIFICATION The detailed mechanical design, thermo structural analysis, cooling system design of the diffuser shall be carried out by the Contractor. The tentative details of the diffuser components are described below:
4.5.3.1 SCOOP ASSEMBLY ASSEMB LY The scoop assembly is a convergent duct followed by a straight cylindrical duct. The inlet diameter of the scoop assembly is 1.8 m. The convergent duct has two steps: 15 0 and 80 convergence. The scoop assembly moves telescopically inside the constant area duct over a length of 2m which is operated off-line. The positions of the scoop vary from 0.8m to 2.8m from nozzle exit. The scoop assembly should be sufficiently strong to take thrust load of flow. Thermal coating may be provided inside the scoop assembly to take care of the high temperature effect. The scoop shall be mounted on the scoop mechanism with suitable support structure for axial movement. Scoop mechanism need to be fixed inside the test section.
The details of the scoop assembly are given in Fig. 4.11. 4.11.
100
Vacuum isolation valve
Test section
Sub-sonic diffuser assembly
Scoop assembly Bellow
97 0
0 0 8 1
1 5 °
9 96
Ø 1 0 0 0
2500
5 , 8 1
8 °
0 0 0 1
1 2 0 °
50
3 nos. 120 degree apart
Test Section Supersonic Diffuser
scoop mechanism
Fig. 4.1 4.11 1 Schematic Schematic of t he scoop assembly
o
Inlet diameter of the scoop: 1.8 m
o
Semi – convergent convergent angle of the first convergent duct: 150.
o
Semi – convergent angle of the second convergent duct: 8 0
o
Overall length of the convergent duct: 1.97 m 101
0 2 0 1 Ø
o
Inside diameter of constant portion of scoop: 1 m
o
Length of the straight portion: 2.5 m
o
Design pressure: 0.4 MPa
o
Flow Temperature: 1400 K (maximum)
o
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).
o
The scoop assembly may be welded/ divided into two segments
o
SS 310 or any other equivalent material shall be used
o
Tentative thickness of the shell is 10 mm.
o
To reduce the flow induced vibration from the scoop exit it should have movable guide support in the diffuser.
4.5.3.2 CONSTANT AREA DUCT •
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
: 0.4 MPa (maximum)
•
Flow Temperature
: 1400 K (maximum)
•
Shell temperature to be cooled to
: 333 K
• Material of construction
: ASTM A 516 Gr. 70
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
4.5.3.3 SUBSONIC DIFFUSER ASSEMBLY This is a conical divergent duct interfaced with vacuum isolation valve in the upstream side and connecting duct in the downstream side. The inlet diameter is 1 m and outlet diameter is 2 m and the semi-divergence angle of the diffuser is 2.5 0. The length of the diffuser assembly is 11.45 m. The subsonic diffuser assembly is divided into three segments and assembled together with flange joints using fasteners. The fasteners shall be designed for the working conditions. The joints shall be leak proof in both high pressure and vacuum (vacuum leak rate should not exceed 10 -8 Pa-m3/sec by providing suitable gaskets / sealing. The upstream flange shall be designed to suit with the vacuum isolation valve and downstream flange shall be designed to suit with the connecting duct.
A cooling system is required to cool the diffuser due to high temperature environment. The schematic of the subsonic diffuser assembly is shown in Fig. 4.13.
103
Cooling water ou t
Nozzle
Cooling water in
Nozzle
0 0 1 1
0 0 0 1
5 1
3500
4000
50 0
1500
9500
Guide rail for movable support 3 nos. 120 degree apart
Fig. 4.12 : Schematic of supersonic (constant area) diffuser Cooling water out
Nozzle
Cooling water in
Nozzle Nozzle
2 , 5 °
0 0 0 1
0 0 0 2
Ø
Ø
4000
4000
3450
11450
Fig. 4.13 : Schematic of Subsonic diffus er
104
The specifications of subsonic diffuser are given below: Inlet diameter
: 1m
o
Outlet diameter
:2m
o
Semi – divergence angle
: 2.5 0
o
Overall length
: 11.45 m
o
Design Pressure
: 0.4 MPa
o
Flow temperature
: 1400 K
o
Material of construction
: ASTM A 516 Gr. 70
o
Shell temperature to be cooled to : 333 K
o
Design
o
: 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.
The specifications of subsonic diffuser are given below: Inlet diameter
: 1m
o
Outlet diameter
:2m
o
Semi – divergence angle
: 2.5 0
o
Overall length
: 11.45 m
o
Design Pressure
: 0.4 MPa
o
Flow temperature
: 1400 K
o
Material of construction
: ASTM A 516 Gr. 70
o
Shell temperature to be cooled to : 333 K
o
Design
o
: 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.
4.5.3.4 COOLING SYSTEM The diffuser needs to be cooled externally to withstand high temperature of the flow. The Contractor shall carry out the cooling system design, detailed engineering, cooling water pumping requirements; fabrication for cooling system shall be supplied along with the diffuser assembly. Provisions for mounting one temperature sensor at outlet and two pressure sensors at inlet & outlet shall be provided.
4.5.3.5 SUPPORT STRUCTURE The diffuser assembly shall be mounted on support structures. Each segment shall be provided with separate support structure. The support structures for the supersonic diffuser will be movable on rails whereas support structures for subsonic diffuser will be fixed directly to floor. The centerline of the diffuser is fixed at a height of 1.5m from the building floor. A suitable height adjusting mechanism shall be provided on the support to take care or a height variation of ±50 mm and lateral adjustment of ±50 mm. Support structure shall be made out of structural steel.
4.5.3.6 MEASUREMENT PORTS Measurement ports will be provided on each segment of the diffuser wall for pressure and temperature measurement. Suitable adaptor shall be provided for pressure measurement for nullifying the temperature effect (i.e., reduction from stagnation temperature to ambient 105
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.
4.5.4 ACCEPTANCE TESTS The diffuser assembly shall be integrated and shall be pneumatically tested for 0.4 MPa internal pressure and vacuum leak rate test (10 -8 Pa m3/s) at Contractor’s site during inspection.
4.6 VACUUM ISOLATION VAL VE The vacuum isolation valve is integrated with constant area duct in the upstream end and subsonic diffuser in the downstream end. The specifications of the vacuum isolation valve are given below: VAT series DN 1000 large HV gate valve with a mechanical interlock for open position of the valve Quantity
: 1 No.
Type
: With position indicator and solenoid
Body material
: Stainless steel (appropriate grade)
Sealing material
: Gate: VITON; Bonnet: VITON (appropriate grade)
Make
: VAT / GMBH
Valve shall be supplied with spare kit. Limit switches shall be provided for indicating the extreme position of the valve. This valve operation is very critical from tunnel operation point of view. Hence at sensor level, triple mode redundancy is to be provided.
4.7 CONNECTING DUCT 4.7.1 INTRODUCTION: Connecting duct is the interface between diffuser and after cooler.
4.7.2 SYSTEM CONFIGURATION A schematic diagram of the connecting duct along with after cooler is shown in Fig. 4.14
106
Aftercooler Sub-sonic diffuser assembly Vacuum isolation valve
Connecting duct Bellow Scoop assembly
assembly
Water jacket Connecting duct
Aftercooler
Man hole
ground level
Fig. 4.14 Schematic of the connecting du ct 4.7.3 TECHNICAL SPECIFICATION Quantity
: 1 no.
Entry diameter
: 2000 mm
Operating flow temperature
: up to 1400 K
Design code
: ASME code pressure vessels Section – VIII, Division -1
Wall temperature to be cooled to: 333 K Note - A manhole shall be provided at the bottom.
107
4.7.3.1 MECHANICAL DESIGN Mechanical design of the connecting duct includes the shell design, the type of joints, assembly with diffuser and Aftercooler. The connecting duct needs to be designed to withstand both 4 bar internal pressures as well as 0.01 mbar vacuum. It shall be designed as per ASME code and the shell temperature shall be maintained at 333 K. Contractor needs to design the cooling system for the connecting duct, if necessary. The material of the connecting duct is proposed to be SA516 – grade 70.
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 m 3/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.
4.7.3.3 MAN HOLE A manhole shall be provided in the duct as shown in Fig. 4.14. The door for the manhole shall be leak proof both at high pressure and vacuum and the vacuum leak rate should not exceed 10-8 Pa m3/s.
4.7.3.4 SUPPORT STRUCTURE The connecting duct will be mounted on support structures (If necessary). Support structure shall be made out of structural steel. 4.7.4 ACCEPTANCE TEST Hydrostatic test as per standard and vacuum leak rate test (10 -8 Pa-m3/sec) as acceptance test shall be carried out at the Contractor’s site during inspection.
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 Manufacturer’s 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
Fig. 4.15 schematic arrangement o f Af tercooler
4.8.2 FUNCTIONAL REQUIREMENT AND SPECIFICATIONS Aftercooler shall be used for online cooling of hot air coming from the diffuser at different mass flow and temperature. It will cater to the complete operating conditions of the tunnel as shown in Table 4.4. The requirements of the system are defined below. •
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. •
Specifications are given in Table 4.5.
•
Proposed Material for different components of Aftercooler is given in Table 4.6.
•
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
Different Operating condit ions for Aftercool er
Inlet pr essure to
Ai r m ass fl ow rat e
Ai r Inl et t emp .
Kg/s
K
Pa
5
61.38
346
30858
5
119.55
364
61716
5
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
8
6.54
653
4244
8
12.80
682
8488
Mach No.
110
Af ter co ol er
8
18.94
700
12732
8
25.02
714
16976
8
31.04
725
21220
8
37.02
734
25463
8
42.96
742
29707
8
48.86
749
33951
8
54.74
755
38195
8
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
Table 4.5 Specifi cation o f A ftercooler Type
of
heat
Shell-and-tube
heat
exchanger
exchanger
(fixed tube sheets construction)
Shell configuration
Counter flow
Shell side fluid
Coolant (water)
Tube side fluid
Working fluid (air)
Air outlet temperature
≤ 333K
Placement
Horizontal, fixed
Table 4.6 Proposed Material For different components of Aftercoo ler Component
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
Water piping shall be made of carbon steel ASTM A53B / 106B.
Table 4.7 Standards to be follow ed in system design Description
Standard/code
After cooler
TEMA/ ASME sec. VIII
Piping
ANSI B 31.3/31.1
SS pipes
ANSI B 36.19
CS pipes
ANSI B 36.10
Butt welded fittings
ANSI B 16.9
Socket welded / threaded fittings
ANSI B 16.11
Flanges
ANSI B 16.5
Stud (fully threaded), Nuts & Washers
ASTM A 193 B8/ B7, A 194 8B/ 2H
Gaskets
API 601 /ANSI B 16.5
Non return valves
BS 5352/ API 6-D
Pressure gauges
BS 1780/IS 3624
Hydraulic pressure test of pipelines
ASTM A 530
112
NDT
ASME Section V
Welding
ASME Section IX, AWS
Radiography
ASTM E 94
Design & Fabrication
ASME Section VIII, division I
4.8.3 INSPECTION & TESTING All the bought-out materials and the works during fabrication at the Contractor’s factory and erection at the Department’s site shall be inspected by one of the following reputed Third Party Inspection Agencies. (TPIA) •
Lloyds Register Industrial Services Pvt Ltd (LRIS)
•
Bureau Veritas Industrial Services Pvt Ltd (BVIS)
•
Det-Norske Veritas (DNV)
•
Any other Govt. Approved Agencies
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
b.
Identification of different component of the system with test and calibration certificates.
c.
Witnessing of welding procedure qualification and welder’s performance qualification tests. If the welders already possess the performance certificate, the TPI agency 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.
4.8.3.1
ACCEPTANCE TEST FOR AFTER COOLER:
Following are tests to be performed for acceptance of Aftercooler •
Material Certificates: The material Certificates, detailing the physical and chemical properties, of the principal pressure-bearing parts shall be provided.
•
Hardness test
•
Magnetic particle examination
•
Tare mass measurements
•
Water capacity measurement 113
•
Hydraulic pressure test as per ASME sec. VIII/TEMA
•
Ultra – sonic test for flaw detection
•
Dimensional check
•
Functional test: The Aftercooler with all accessories mounted shall be subjected to functional test to validate the performance for all operating condition.
•
Wall thickness measurement by ultra-sonic probe at identified points (the location of the pressure vessels are sketched on drawing with reference to a fixed point on the pressure vessels).
•
Dye penetrated test and radiographic test with x-rays or gamma rays to 2-T sensitivity of all butt welded joints.
4.8.3.2 ACCEPTANCE TEST FOR COOLING SYSTEM 4.8.3.2.1 VALVES •
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 t he 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). •
Cleanliness: The pipes shall be cleaned and dried before dispatch.
•
Marking: The pipes shall be marked as per ASTM A 700.
4.9 SCOPE OF WORK FOR TUNNEL SYSTEM 4.9.1 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. 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.
However, it is the responsibility of the Contractor to ensure the soundness of the design to meet the functional requirements of the systems.
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.
4.9.4 INSPECTION AND TESTING I. Inspection and testing requirements, acceptance standards shall be identified at different stages of realization of the system through process and QC plan. Critical stages of realization will be identified in the process/QC plan right from raw material qualification to the final stage of the system and also erection and commissioning. Fabrication process and QC plan will be approved by the Department before initiation of fabrication. II. Critical stages shall be identified, where TPIA shall be involved to carry out surveillance inspection III. 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.
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 Contractor’s responsibility to arrange for and co-ordinate with the TPIA
4.9.5
DOCUMENTATION
Three copies of the following documents have to be submitted by the party I. Design documents, analysis reports for each system approved by TPIA II. Fabrication drawings, process plan and QC plan III. Inspection reports at each stage of realization systems certified by TPIA IV. Reports of tests/acceptance carried out for the bought out components V. Reports of mandatory acceptance tests VI. Consolidated reports, system wise, in a document form shall be submitted to the Department for approval/acceptance VII. Report of the functional test of the facility in the integrated condition
4.9.6 INTEGRATION AND COMMISSIONING I. The sub-systems/systems realized and qualified at stage level, shall be integrated as laid out in the document II. The Contractor shall work out the detailed plan for integrating the systems realized by them. Facilities/equipments/infrastructure needed for the task shall be totally taken care by them. The electrical power requirements shall be informed to the Department and the same shall be provided on chargeable basis III. The Contractor is also responsible for integrating the tunnel systems with other system. IV. The Contractor shall carry out functional test, in the integrated condition, ensuring the performance of all systems to the specified requirements. V. In the event of not meeting specified requirements by any of the systems realized by them, the same shall be attended to and necessary modifications to be carried out to make it operational in all respect.
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 DELIVERAB LES The list of deliverables is given in the table below: Sr.
Item
no.
Qty.
Settling Chamber- Pressure shell, insulation liners, perforated 1.
plates (flow manipulators), support system with wheels and
2 nos.
associated piping. 2.
Nozzle - Pressure shell, cooling system for throat, test section interface, support system with wheels and associated piping
5 nos.
Test section- Two sliding doors with flanges to mount schlieren 3.
glass windows, compartments with interfacing of nozzle, scoop and
1 no
diffuser, safety devices, etc Model Incidence Mechanism- with actuators, hydraulic power 4.
1 no
pack, accumulator, hoses, safety devices, instrumentation and standalone control system etc. Diffuser – with scoop assembly, supersonic diffuser, subsonic
5.
diffuser, expansion bellow, interface with vacuum isolation valve, cooling system, associated piping, and pipe fittings etc.
1 no+1 no. of expansion bellow 1 no+1 no.
6.
Vacuum Isolation Valve
7.
Connecting duct- with manhole, cooling system etc
1 no.
8.
Af ter co ol er- with coolant circulation system, cooling tower etc
1 no.
Note: The number prefixed by ‘+’ are the additional requirement
119
CHAPTER 5 Instru mentatio n and Contr ol Syst em 5.0 INTRODUCTION Hypersonic wind tunnel is an experimental aerodynamic test facility which simulates hypersonic flight conditions. Measurements are performed on the test article & also on the facility during simulation and by which aerodynamic coefficients are deduced. The facility contains critical subsystems such as high pressure system at 300 bar pressure, vacuum system at 0.01millibar pressure, 120MT capacity LPG storage & handling system, LPG burner- blower system and storage heater at 1700K temperature. High pressure (300bar), high temperature (1700K) air is used as a test medium for conducting the tests. The sensors are very critical since these are subjected to 100 bar pressure & 1700K temperature.
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.
5.1 FACILITY DESCRIPTION Hypersonic wind tunnel facility is divided into major subsystems as given below. a) High Pressure System (HPS) b) Pressure Regulation System (PRS) c) Air Heating System (AHS) d) Tunnel System e) Vacuum System f) Cooling System
The schematic of the facility is shown in Fig. 5.1. HPS comprises of air storage cylinders and compressors. Compressor provides the compressed high pressure dry air, which will be stored in cylinders. This system provides the required volume of air for tunnel operation. EGV 4 is a electro–pneumatic (EP) / electro-Hydraulic (EH) actuated ON/OFF type valve which isolates the PRS from HP system. PRS is used for maintaining the steady pressure in the settling chamber. PRS consists of three parallel circuits. Depending on the mass flow requirement, one of the parallel circuits is used for blow down. In each parallel circuit, three valves are connected in tandem. First valve is EP (or EH) actuated ON/OFF type. Second 120
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 (HSV’s). All the HSV’s 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 ( α,β,φ) 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.
5.2 TUNNEL OPERATING SEQUENCE The typical operating sequence of the tunnel for one blow down is as follows: HP system, Air Heating System and Vacuum System are the three subsystems which are operated simultaneously in isolated mode by using their own stand alone system until desired test conditions achieved. In other words, these systems are at ON condition during blow down preparation time till desired conditions are achieved and these are at OFF position during
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 tunnel–off 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.
5.3 FUNCTIONAL REQUIREMENT OF INSTRUMENTATION SYSTEM Instrumentation system should be designed for performing the following functions. a) Precise, reliable, safe, automatic operation & control of tunnel during blow down. b) Acquisition of various types of parameters on the model & also on the facility. c) Centralized monitoring of health of the subsystems from the tunnel main control room.
Based on these functions, the instrumentation system is classified as Control System, Measurement System and Health Monitoring System respectively.
5.3.1 FUNCTIONAL REQUIREMENT OF CONTROL SYSTEM: Control system should operate & control the tunnel very precisely as per the time bound (i.e., event bound) pre-defined sequence. During blow down, control system should control PRS system and MIM system in closed loop. In addition to this, it also operates the valves which are present in the tunnel circuit. 122
Additional requirements from control system is a) Tunnel operation should be fully automatic with remote monitoring and manual override. b) Real Time display of control parameters during blow down. c) System should be of fault tolerant design in terms of software and hard ware. Redundant & voting systems are to be incorporated for all components required for controlling of tunnel. In case of any kind of fault, it should tolerate and bring the tunnel to the safe state. d) Provision of emergency shut down button in tunnel main control room for emergency stopping of the tunnel. e) Deterministic execution of control loops. f) Subsystem controllers should be of modular design, which is required for either isolated or integrated mode of operation of subsystem controllers with master controller. g) Configured
as
a
automated
check
out
system
for
functional
checking
of
valves/subsystems before actual test.
The desired features of this system is as follows a) Testability for functional check b) Availability of components in the future (COTS are preferable) c) Should be of well proven state-of-the-art technology d) Flexibility in modifying the test code (software) as per requirement e) System should be expandable in terms of channel count f) Suitable to the test environment conditions g) Pass word protection for unauthorized access deny h) EMI/EMC, CE compliances
The contractor has to work out the scheme of control system for meeting functional requirement and supply the same. The proposed system should have above desired features. Distributed control system approach is preferable.
A) Closed lo op operat io n of press ur e reg ulati ng syst em: It is to be tuned such that it maintains steady pressure in the settling chamber within the prescribed limits for the desired test duration. The control loop becomes a multi input single output system. The block diagram of control loop pertaining to the PRS system is shown in Fig. 5.2.
Design conditions are a) Flow stabilization time in the settling chamber ≤ 5seconds 123
b) Steady state error < 1% of set value c) Peak over shoot < 5%. d) PRV final opening is not more than 90%. Tunnel will be operated at different operating conditions. At each operating condition, desired set conditions vary. Based on the valve characteristics & operating conditions, the contractor has to tune the control loop by choosing appropriate control algorithm such as PID, Fuzzy logic, MFA method etc.
The contractor has to perform Hardware-in-loop simulation and also demonstrate the performance at each & every operating condition by simulation and also the same with the actual test setup at actual test conditions.
B) Closed loop operation of MIM: It is to be designed such that MIM is operated as per the time bound pre-defined sequence at any cost. MIM system is a mechanical linkage system to which model is attached. MIM has to perform three functions sequentially. These are model injection, model sweep and model withdrawal. Model injection is nothing but bringing of model from tunnel off-axis to tunnel axis. Model sweep means varying of model orientation (α,β,φ) either in pitch-pause mode or continuous operation mode at pre-defined speed depending on the test requirement. Model withdrawal means bringing of model from tunnel axis to tunnel off-axis. Initially, MIM system is positioned at the tunnel off-axis (i.e., lower compartment of the test section) until the flow is stabilized in the test section. After stabilization of flow, MICS execute its three functions as per pre-definition.
Design conditions for MIM are given in Table 4.3. The contractor has to configure dedicated stand alone control system for MIM operation. This controller should work in handshaking mode with tunnel master control system which is required for automatic operation of the tunnel. This controller should have a local panel with display (in the field) to feed the test conditions and for functional checking before the blow down. But during actual blow down, local display option is disabled and this control system works as per the instruction of tunnel master control system.
Based on the input conditions, the contractor has to tune the control loop by choosing appropriate control algorithm such as PID, Fuzzy logic, MFA method etc..
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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.
5.3.2 FUNCTIONAL REQUIREMENT OF MEASUREMENT SYSTEM Measurement system should be designed for acquisition of various types of parameters on the model & also on the facility. Model parameters consist of steady pressure, unsteady pressure, force & moments and temperature/heat flux. Facility parameters consist of pressure and temperature.
Measurement system is to be designed such that digitization is done near the measurand which avoids noise intrusion and number of cables requirement. It should be a trigger based data acquisition (DAQ) system. Data acquisition should be started & stopped upon receiving of trigger signal (i.e., analog or digital) from tunnel control system. DAQ system should update its running status periodically (say every 1miili second) to the operator and also to the tunnel control system.
Data acquisition is to be carried out at pre-defined
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.
5.3.3 FUNCTIONAL REQUIREMENT OF HEALTH MONITORING SYSTEM: Health monitoring system should facilitate the provision for centralizing monitoring of health of tunnel subsystems. In contrast, SCADA based GUI environment is to be created in the 125
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.
5.4 INDICATIVE BLOCK DIAGRAMS The indicative block diagrams of instrumentation system are presented in this section. These diagrams are given only for the reference for understanding about the system. But the contractor is free to choose the better configuration acceptable by the department for meeting functional requirement.
5.4.1 CONTROL SYSTEM Indicative block diagram of control system is shown in Fig 5.3. As per this approach, one exclusive control system is provided for closed loop operation of MIM system. Master control system is reserved for closed loop operation of PRV, operation of valves which are present in the tunnel circuit and MIM controller coordination. Individual control systems and Host PC are connected by the dual data network. Host PC is placed in the control room. Host PC displays the control parameters in real time. All the components of the control system will have redundant components for making it fault tolerant. In case of any type of 126
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.
5.4.2 MESAUREMENT SYSTEM: The indicative block diagram of measurement system is shown in Fig 5.5. Measurements are classified based on the sampling rate requirement, type of measurement and location of measurement. Based on this classification, multiple Real Time Data Acquisition Systems (RTDAS) are configured. Each RTDAS works as a stand alone system which executes data acquisition code in autonomous mode. All RTDAS will have time synchronization. During the test, data is stored in the respective RT DAS & few channels (user selected) data is displayed in the Host PC in real time. After the test, data is automatically transferred to the HOST PC & Data server.
The measurements performed on the facility and model is termed as facility measurements and model measurements respectively. Facility measurements are distributed around 100m span from control room and hence one or more RTDAS may be needed.
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
1Megasample/sec/channel. Rest of the measurements viz. steady pressure using independent pressure transducers, force & moment and temperature are performed with low speed DAS as sampling rate requirement is 30Ksamples/sec/channel (max).
Typical block diagram of RTDAS is shown in Fig 5.6. Sensor output is the order of few mV and hence conditioned using suitable signal conditioner for increasing SNR. Sensor, signal conditioner and embedded controller are inter-connected by STP instrumentation cable. Embedded controller consists of input modules, ADC, deterministic processor, application software, RTOS, display unit etc... Embedded controller connected to the host PC via data network. Before the test, data acquisition code is deployed into controller. During the test, data is stored in the embedded controller with proper time stamping. After the test, the data is automatically transferred from embedded system to Host PC. Data processing & analysis is carried out in the host PC.
5.4.3 HEALTH MONITORING SYSTEM: The indicative block diagram of health monitoring system is shown in Fig 5.7. High pressure system, Air Heating System and Vacuum System are the three major subsystems which are operated simultaneously before the test until desired conditions are achieved. Each of these systems will have dedicated stand alone control system for their operation. These control systems will be realized by the respective subsystem supplier. Even though these systems will have stand alone control system with local display, SCADA based GUI environment is essential at main control room for centralizing monitoring of tunnel subsystem operation.
Health monitoring system consists of large display units equipped at main control room to facilitate display of subsystem/system mimics. The mimics are organized such that it provides quick information about subsystem health. It displays critical parameters data in the user selectable format like graphical, digital, LED etc..
The critical parameters are
tapped from the respective control panels. Data historian server acquires the data of critical parameters at low sampling rate (say 10samples/sec). 128
5.5 INSTRUMENTATION SYSTEM COMPONENTS REQUIREMENT Unless otherwise specified, supplying of all components required for meeting functional requirement of instrumentation system is under scope of instrumentation system contract. Supplying some of the components such as actuators, servo valves and solenoid valves is not under scope of instrumentation system contract.
5.5.1 SENSORS & CHANNELS REQUIREMENT In the following sections, sensors requirement (tentative) at tunnel subsystems and I/O channels requirement (tentative) at the instrumentation system subsystems is presented. Instrumentation system subsystems include Master Control System (MCS), Measurement System (MS), Model Incidence Control System (MICS) and Health Monitoring System (HMS). Note: I/O channel count, given in this section, is finalized in the view of indicative block diagrams as shown in Fig 5.3 to Fig 5.5 & Fig 5.7. I/O channel count may vary with different configuration scheme.
5.5.1.1 HIGH PRESSURE SYSTEM A. Cylinders (Pressure Vessel) i) For storing of high pressure blow down air, 36 numbers of cylinders are planned. Six cylinders are grouped as one module with a common manifold. Each module is connected to main manifold by a valve. These valves are operated by High pressure control system. In other words, operation of these valves is not under instrumentation system contract scope. Depending on the requirement of the volume of air for blow down, numbers of modules are opened. Opening or closing status of these valves is to be known to MCS for ensuring requisite air storage volume before starting the blow down. Requirement: DIN –2 for each v alve Signals terminated at MCS:
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 No’s
2) RTD QTY: 1 No Signals term inated at MCS: ANALOG IN – 3 129
Signals termi nated at MS:
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 monito ring Sensor Required 1) PT
QTY: 2 No’s (1No for redundancy)
Signals term inated at MCS: ANALOG IN - 2 DIG IN - 2
iii) Electro-Pneumatic Globe Valve (EGV4) is an ON/OFF type valve for isolation of tunnel circuit from the high pressure system. This valve is operated by MCS. Triple mode redundancy (TMR) is planned for this valve. Requirement: DIN – 6 for status (4No’s for redundancy) DOUT – 3 for control (2No’s for redundancy) Signals term inated at MCS: DIG IN - 6 DIG OUT - 3
EGV4 valve should be in closed position except during blow down. This valve status is to be monitored by health monitoring system. Signals t erminat ed at HMS: DIG IN – 4 (2No’s for redundancy)
B. Compressor Contro l Panel Two compressors are planned for the delivery of required pressure. Control system for operation of compressor will be designed & supplied by the HP system supplier. In other words, realization of control system for HP system is not in the instrumentation system contract scope.
One Ethernet channel (TCP/IP protocol) is to be terminated in the HMS for the health monitoring purpose during operation of HP system. This channel contains the information of HP system process parameters. Signals term inated at HMS: Ethernet channel – 1 130
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 term inated at MCS: DIG IN- 4
5.5.1.2 PRESSURE REGULATING SYSTEM Three parallel circuits are planned for operating the tunnel at wide range of M-Re conditions. One of the three will be used for the blow down. In each parallel circuit, three valves are connected in tandem.
A. EGV 5/6/7 : This valve is ON/OFF type EP (or EH) valve. This valve is operated by MCS. TMR is planned for this valve. Requirement:
DIN – 6 for statu s
for each valve (4 No’s for redundancy)
DOUT – 3 for contr ol
for each valve (2 No’s for redundancy)
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:
for each valve ANALOG IN - 2 No for po si ti on measur ement (1No for redundancy) ANA LOG OUT - 3 No f or co nt ro l (2No’s for redundancy) COUNTER IN - 1 No for position measurement using Linear / rotary encoder (different scheme for reliability) DIG IN
- 4 No for extreme posit ion indication (2No’s for redundancy)
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:
DIN – 2 for status for each v alve
Signals terminated at MCS: ANALOG IN - 6 ANALOG OUT - 9 COUNTER IN - 3 131
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. Senso rs Required: PT
QTY: 2No’s
Signals terminated at MCS: ANALOG IN- 2 DIG IN - 2
5.5.1.3 AIR HEATING SYSTEM A. Cont ro l Pan el for AHS Two heaters are planned for meeting the operational requirement. Control system for the heater operation includes LPG storage & handling control, burner-blower control, heater thermal control etc… This will be designed & supplied by the air heating system vendor. In other words, control system for air heating system is not under instrumentation system contract scope.
One Ethernet channel (TCP/IP protocol) is to be provided at the HMS for the health monitoring purpose during operation of air heating system. This channel contains the information of air heating system process parameters. Signals term inated at HMS: Ethernet channel - 1
During the blow down, heating system should be in OFF condition. Heating system running status (ON/OFF) and readiness of heater for t he blow down is communicated to the MCS. Signals term inated at MCS: DIG IN - 4
B. Heater v essel 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 No’s
2) Thermocouple assembly with thermow ell QTY: 4 No’s Signals term inated at MCS: ANALOG IN- 8 132
Signals term inated at MS: ANALOG IN- 8 C. Hot s hut off valves (HSV) Four HSV’s are planned for each heater. HSV’s are ON/OFF type EP (or EH) valve. HSV 5 & HSV 6 are at closed position & rest of the HSV’s are at open position during the blow down. HSV 5 & 6 are operated by the heater control system. In other words, operation of HSV5 & HSV6 valves is not under instrumentation system contract scope. Rest of the HSV’s operation is in the instrumentation system contract scope and is to be done by MCS. TMR is planned for these valves. Requirement: For each valve DIN - 6 for st atus for HSV1 to HSV 8 (4No’s for redundancy) DOUT-3 for c ont rol for HSV1 toHSV4 & HSV 7 to HSV 8 (2No’s for redundancy) Signals terminated at MCS: DIG IN - 48 DIG OUT - 18
During offline, On/Off status of these valves is to be monitored by health monitoring system. Signals termi nated at HMS:
DIG IN - 32
5.5.1.4 VACUUM SYSTEM Two identical chains of vacuum pumping systems are planned for getting desired level of vacuum in pre-defined time in the Horton spheres and test section. Control system for operation of vacuum pumps will be designed & supplied by the vacuum system supplier. In other words, control system pertaining to the vacuum system is not under instrumentation system contract scope. A. Contr ol Panel fo r VS One Ethernet channel (TCP/IP protocol) is to be provided at the HMS for the health monitoring purpose during operation of vacuum system. This channel contains the information of vacuum system process parameters. Signals term inated at HMS: Ethernet channel - 1
During the blow down, vacuum system should be in OFF condition. Vacuum system running status (ON/OFF) and its readiness for the blow down is to be communicated to the MCS. Signals termi nated at MCS:
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.
C. Vacuu m Isolati on Valve This is the most critical valve 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. The status of this valve needs to be doubly verified to ensure safety. Different schemes like mechanical or optical sensors may be employed to indicate the ON/OFF status of the valve. One safety latch is to be provided to ensure that the valve is not closed by accident. This signal is to be included as an interlock in the control software. This valve is operated by MCS.
Requirement: DIG IN - 6 No for status (4 No’s for redundancy scheme) DIG OUT - 3No fo r co ntr ol (2 No’s for redundancy) Signals termi nated 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 termi nated 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 No’s for redundancy) Signals termin ated at MCS: DIN – 3
5.5.1.5 TUNNEL SYSTEM 5.5.1.5.1 SETTLING CHAMBER Two settling chambers (SC) are planned. SC1 for M5 & M6.5 operation. SC2 for M8, M10 & M12 operation.
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) Pressur e Transdu cer - QTY: 12 No 2) Thermoc oupl e assembly - QTY: 4 No Signals term inated at MCS:
ANALOG IN - 16ch
Signals term inated at MS:
ANALOG IN - 16ch
5.5.1.5.2 TEST SECTION In the test section, the following measurements are planned. Sensors Required: 1) Nozzle exit press ure - 2 No (1 No for redundancy) 2) Plenum chamber press ure - 2 No (1 No for redundancy) 3) Vacuum gauge - 2 No (1 No for redundancy) 4) RTD
- 2No (1 No for redundancy)
Signals term inated at MCS: ANALOG IN - 8ch Signals termi nated at MS:
ANALOG IN - 6ch
For the tunnel operation, the following signals are required i) The flow visualization system readiness is communicated to MCS as a DIG IN. ii) The control panel of the test section vacuum system needs to communicate test section vacuum readiness status to MCS as a DIG IN. iii) The closing/opening status of the test section is communicated to MCS as a DIG IN. iv) For knowing the capture tube position, two DIG I N signals are required.
Signals term inated at MCS:
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 (2No’s for redundancy)
Position Feedback / angular feedback 3 ANALOG IN (2No’s 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
Signals terminated at MICS (tentative): ANALOG IN - 6ch ANALOG OUT - 12ch Counter IN - 6ch DIG IN - 44ch Signals terminated at MCS: An alog IN - 9ch Counter IN - 6ch Signals terminated at MS: ANALOG IN - 9 ch Counter IN - 6ch
5.5.1.5.4 SUPERSONIC & SUBSONIC DIFFUSER 10 pressure measurements & 2 temperature measurements are planned on the diffuser. Sensors Required: i) Pressur e Transduc ers
-
ii) Thermoc oupl e assembly -
QTY: 10 No’s QTY: 2 No’s
Signals term inated at MS: ANALOG IN - 12ch Signals term inated at MCS: ANALOG IN - 4ch 136
5.5.1.5.5 AFTER COOLER Two pressure measurements & two temperature measurements are planned on the after cooler. Sensors Required: i) Pressur e Transduc ers
- QTY: 2 No’s
ii) Thermoc oupl e assembl y
- QTY: 2 No’s
Signals term inated at MS: ANALOG IN - 4ch Signals term inated at MCS: ANALOG IN - 4ch 5.5.1.6 MODEL MEASUREMENTS Total 220 measurements are planned on the model. It includes steady pressure, unsteady pressure, forces & moments and temperature. The sensors required for model measurements will be supplied by the department. Other components of the measurement system (i.e., excluding sensor) are to be supplied by the contractor.
A. Steady pr ess ur e m easurem ent: It is planned to perform using independent pressure transducers and ESP pressure scanners. Independent pressure transducer provides analog interface usually of the order of few milli Volts. Measurement system is to be configured for 16 channels of independent pressure transducers data. Signals term inated at MS: ANALOG IN - 16ch ESP Pressure Scanners are miniature electronic differential pressure measurement units consisting of an array of silicon piezoresistive pressure sensors, one for each pressure port. ESP Pressure Scanner of 32 channel capacity each is planned. Measurement system is to be configured for 4 numbers of ESP scanner data. I/O details for each scanner: Digital output signal -2 (RS-485) Ethernet-2 Signals termi nated at MS:
RS-485
- 8ch
Ethernet
- 8ch
B. Unsteady pressure measurement:
Miniature, high bandwidth, dynamic pressure
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
Signals term inated at MS: ANALOG IN - 24ch
C. Forces & moments measurement:
Strain gauge type balance is used. Measurement
system is to be configured for 4 numbers of stain gauge balances data. Each balance needs 7 numbers of analog channels. It provides analog interface usually of the order of few milli Volts. Signals term inated at MS: ANALOG IN - 28ch
D. Temperature / heat flux measurement: For these measurements, either heat flux gauge or Thermocouple is used. Measurement system is to be configured for 24 channels of temperature data. Signals term inated at MS: ANALOG IN - 24ch
5.5.1.7 Water coo lin g Water cooling is proposed at the following subsystems. Each cooling circuit contains one pressure transducer at inlet, one temperature & pressure transducer at outlet. Number of cooling circuits is shown against each subsystem. a. HSV1 to HSV8 b. Pipeline
- 1 No each
- 1No
c. Settling chamber - 1No d. Nozzle - 1No e. MIM - 2No f.
Diffuser - 1No
g. Connecting Duct – 1No
Sensors Required 1) PT- QTY: 30 No’s 2) Thermoc oupl e assembly - QTY: 15 No’s Signals term inated 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 term inated 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 termi nated at MCS: DIG IN - 10ch DIG OUT - 10ch Signals termi nated 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
Signals termin ated at MICS:
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:
Pressure Transducers - QTY: 3 No’s Water Level indicato r - QTY: 1No Temperature – QTY: 1No
Signals termi nated at MCS: ANALOG IN - 4 Overall sensor requirement, which are to be supplied by the contractor, for the facility is given in Table 5.1. Subsystem wise numbers of signals (tentative) terminated at subsystems of instrumentation systems are given from Table 5.2 to Table 5.5. Detailed specifications of these sensors are given in Table 5.6. Pressure sensor should be of reputed make like DRUCK, KULITE etc... Temperature sensor should be of reputed make like Omega, Nanmac, Medtherm etc..
5.5.2 OTHER COMPONENTS REQUIREMENT: Based on the sensor count & channel count given in section 5.5.1, the contractor has to work out the quantity of the other components of the instrumentation system required & supply the same. Channel type gives the information about requirement of number of other components is given in Table 5.7.The specifications of the components are given below.
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: ADC’s are required for digitization of control system feedback
signals & measurement signals. ADC spec if ic ati on s: •
Resolution -16 bits minimum
•
Input ranges - 4 discrete steps (programmable)
•
Input impedance - 100 MΩ minimum
•
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%
•
Sampling rate – Programmable
•
Maximum sampling rate as indicated 1. Model Measurements Independent pressure transducer – 1Ksamples/sec/channel o ESP scanner- Not Applicable o Unsteady pressure transducer – 1Mega samples/sec/channel o Forces & Moments using strain gauge balance- 30 Ksamples/sec/channel o Temperature / heat flux using thermocouple, heat flux gauge - To be defined o 2. Facilit y Measurements Independent pressure transducer – 1Ksamples/sec/channel o Temperature using thermocouple - 1Ksamples/sec/channel o
3. Control loop feedback Measurements – 1Ksamples/sec/channel • Minimum sampling rate – No minimum. 140
•
Other specifications are defined at later stage.
DAC’s 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 PC’s: 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
tunnel operation & also for SCADA based GUI environment. Quantity: 10 No’s
5.5.2.10 INTERPERSONAL WIRE LESS HANDS FREE COMMUNICATION SYSTEM: It is required for the voice communication between field engineer and operator who is sitting in the tunnel main control room. Quantity: To be catered for 6 persons
5.5.2.11 SURVEILLA NCE CAMERA: Suitable cameras are to be provided at strategic locations for monitoring tunnel subsystems. The monitoring provision should be made available in control room. Quantity : 7 No’s
5.5.2.12 UNINTERRUPTED POWER SUPPLY (UPS) The contractor has to work out the capacity of the UPS power supply required for the operation of entire tunnel instrumentation system. Based on the data, the contractor has to supply two numbers of UPS of required capacity each. Points to be noted: 1. Even though some of the required items are not appeared in the above list, the contractor has to supply all the items which are required for meeting functional requirement by considering instrumentation system as a turn key project. 2. The contractor should take up minor modifications in the scope of work while execution of project. 3. Data acquisition system make should be M/s National Instruments. 4. Controller (deterministic processor) hardware should be a real time embedded controller.
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.
Coding of the software with comments as per the user requirements is in
vendor’s 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 t raining regarding the entire operation of the application software and coding of the software to be provided to the department personnel. Plat for m: LabVIEW, LabVIEW RT.
5.7 SCOPE OF WORK BY CONTRACTOR The hypersonic wind tunnel instrumentation system has to be executed as a single system. The scope of work of this system is given below. 1) Detailed design & realization of well proven state-of-the-art system for tunnel operation & control, measurement and health monitoring. The realized system should meet the functional requirement and have desired features as mentioned in section 5.3. This system include sensors, noise immunity instrumentation cables, digital(or fiber optic) data transmission cables& its associated equipments, patch panels, instrumentation racks, signal conditioners, Input & output modules with ADC & DAC’s, embedded controllers (deterministic processors for real time execution of control algorithms), data display terminals, data storage units, interfacing units, power sources etc... 2) Failure mode analysis & coding of software for data acquisition, tunnel operation & control as per the user requirement. Coding is to be done as per IEEE 12207 compliances. 3) Configure & supply of control room equipments like display systems, computers, necessary supporting units/peripherals, etc… as per ergonomic compliances. 4) Installation and commissioning of entire tunnel instrumentation system. 5) Site calibration, demonstration & training on complete instrumentation system. 6) Provide the sources for supply of spares.
5.8 SCOPE OF WORK BY DEPARTMENT Department shall provide the following services. 1. Sensors for model measurements like steady & unsteady pressure transducers, ESP scanners, Strain Gauge Balances, Thermocouples and RTD. 2. Earth pits of 0.5 ohm resistance. However the contractor has to connect various equipments to the earth pits through the proper earth strips. The contractor shall
143
provide the details regarding requirement requirement of number of earth pits, location etc.. to the department.
5.9 INSTALLA INSTAL LA TION & COMMISSIONING The installation and commissioning is to be done as per the departmental terms & conditions. Proper routing & termination of signal cables and power cables form measurand to the control room and from UPS room to the various equipments respectively is the responsibility responsibility of the contractor.
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 ACCEPTANCE TEST PLAN (ATP) Detailed ATP shall be finalized at the time of detailed design review. review. Tentative ATP is as follows. 1. Test certificates, calibration certificates & OEM certificates of all components of instrumentation system should be provided. Calibration certificates should be traceable to national/ international standards. 2. Functional check of all components of instrumentation system is to be carried out at contractor site. Function check on component level, subsystem level and total system level is to be carried out at department.
5.11.1
TUNNEL CONTROL SYSTEM
1. Performance of the PRV control loop at various operating conditions is to be demonstrated against its functional requirements by simulation and also with actual components at site during wind off & wind on conditions. 2. Performance Performanc e of the model incidence control system at various pre-set conditions is to be demonstrated against its functional requirements at site with actual components during wind off & wind on conditions. 3. Functionality of the subsystem controllers is to be demonstrated during isolated mode of operation & also at integrated mode of operation with the tunnel main control system in automatic operation mode. 144
4. Determinism Determinism of embedded embedded controllers is to be demonstrated. demonstrated. 5. Ruggedness Ruggedness of the control system is to be demonstrated demonstrated by inserting inserting various types of faults. 6. Execution of Tunnel operation sequence, emergency shut down sequence and test abort sequences are to be demonstrated during wind off & wind on conditions. 7. Features of the control system will be compared compared against against specified features as given given in section 5.3.1.
5.11.2
MEASUREMENT SYSTEM
1. Component level level functional functional & performance performance checks will will be carried carried out. 2. Performance of the measurement measurement system at various various settings is to be demonstrated demonstrated against its functional requirements at site at actual environmental conditions during wind off & wind on conditions. 3. Features of the measurement measurement system will be compared compared against specified specified features as given in section 5.3.2.
5.11.3 HEALTH HEAL TH MONITORING SYSTEM 1. Performance of the health monitoring system is to be demonstrated against its functional requirements requirements at site at actual environmental conditions. conditions. 2. Features of the health health monitoring system system will be compared compared against specified specified features as given in section 5.3.3.
5.12 DELIVERABLES The list of the deliverables is given in Table 5.9.
Fig. 5.1: 5.1: Schematic Schematic of Hypersonic Hypersonic Wind Tunnel Facilit Facilit y.
145
(PV) PV
PV
Fig. 5.2: 5.2: Block diagram of control loop pertaining to the PRS PRS system
Fig. 5.3: 5.3: Indicative block diagram of control syst em
Fig. 5.4: 5.4: Typical block diagram of control loop
146
Fig. 5.5: Indicative block diagram of measurement system
Fig. 5.6: Typical block diagram of RTDAS
Fig. 5.7:
Indicative block diagram of Health Monitoring System.
147
Fig. 5.8:
Approx . Distances (in meters) of various subsys tems from tunnel contr ol room (Each block is 15m Length X 15m Height)
148
Table 5.1: Overall sensors requirement for the facility
Table 5.2:
Number of signals terminated at Master contr ol syst em
Table 5.1: Overall sensors requirement for the facility
Table 5.2:
Number of signals terminated at Master contr ol syst em
Table 5.3: Number of s ignals terminated at Health Monitor ing System
Table 5.4: Number of signals terminated at Model Incidence Control System
Table 5.5: Number of signals termin ated at Measur ement System
149
Table 5.6: Sensors r equired for facilit y measurements to be suppli ed by the contractor Sl.
Type of
No
Measurement
Type of
Sensing
Range
element
Accuracy (%F.S.)
B.W.
Subjected
Monitor (M)/
(Hz)
conditions
Control ( C)/
Temp (K)/
Aero data (A)
sensor
Interface
Medium
Qty
Location
Remarks
Pressure (Mpa) / Shock (g)/ flow rate (kg/sec) 1
PM
PT
SG/
33Mpa
0.1
10
233 – 323 K
M&C
Analog
Air
2
HP Manifold
233 to
0.5
10
33Mpa
M&C
Analog
Air
1
HP Manifold
0.1
10
313K
C
Analog
Air
2
Low pressure
SOS 2
TM
RTD
--
323 K 3
PM
PT
SG/
1Mpa
SOS 4
PM
PT
5
PM
PT
SG/
cylinder 33Mpa
0.1
1000
313K
C&A
Analog
Air
2
Upstream of
12Mpa
0.1
1000
350K*
C&A
Analog
Air
2
Heater-1
12Mpa
0.1
1000
350K*
C&A
Analog
Air
2
Heater-2
750K
0.5
10
12Mpa
C&A
Analog
Air
2
Heater-1
C&A
Analog
Air
2
Heater-2
Settling
SOS SG/
PRV
SOS 6
PM
PT
SG/ SOS
7
TM
TC
Type-
180kg/sec 8
TM
TC
Type-
1700K
0.5
10
12Mpa 60.6kg/sec
9
PM
PT
10
PM
PT
SG/
12Mpa
0.04
1000
350K*
C&A
Analog
Air
6
12Mpa
0.04
1000
350K*
C&A
Analog
Air
6
SOS SG/
chamber - 1 Settling
SOS
chamber - 2
150
Sl.
Type of
Type
Sensing
No
Measurement
of
element
Range
Accuracy
B.W.
Subjected
Monitor (M)/
(%F.S.)
(Hz)
conditions
Control ( C)/
Temp (K)/
Aero data (A)
sensor
Interface
Medium
Qty
Location
C&A
Analog
Air
2
Settling
C&A
Analog
Air
2
Pressure (Mpa) / Shock (g)/ flow rate (kg/sec) 11
TM
TC
Type-
750K
0.5
10
12
TM
TC
Type-
1450K
0.5
10
12Mpa 180kg/sec 12Mpa
chamber -1
60.6kg/sec 13
PM
PT
SG/
Settling chamber - 2
X
0.04
1000
350K*
C&A
Analog
Air
2
Exit of nozzle
X
0.04
1000
350K*
C&A
Analog
Air
2
Plenum chamber
100KPa
0.1
10
350K
M
Analog
Air
2
Test Section
0.1
10
350K
M
Analog
Air
2
Test Section
0.5
10
X
C&A
Analog
Air
2
Test Section
SOS 14
PM
PT
SG/ SOS
15
PM
VG
CT
-100Pa 16
PM
VG
CT
17
TM
TC/
Type-
100Pa1Pa
RTD
X
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)/
Aero data (A)
sensor
Interface
Medium
Qty
Location
C&A
Analog
Air
2
Settling
C&A
Analog
Air
2
Remarks
Pressure (Mpa) / Shock (g)/ flow rate (kg/sec) 11
TM
TC
Type-
750K
0.5
10
12
TM
TC
Type-
1450K
0.5
10
12Mpa 180kg/sec
chamber -1
12Mpa 60.6kg/sec
13
PM
PT
SG/
Settling chamber - 2
X
0.04
1000
350K*
C&A
Analog
Air
2
Exit of nozzle
X
0.04
1000
350K*
C&A
Analog
Air
2
Plenum chamber
100KPa
0.1
10
350K
M
Analog
Air
2
Test Section
0.1
10
350K
M
Analog
Air
2
Test Section
SOS 14
PM
PT
SG/ SOS
15
PM
VG
CT
-100Pa 16
PM
VG
CT
17
TM
TC/
Type-
X
0.5
10
X
C&A
Analog
Air
2
Test Section
SG/
0.4Mpa
0.1
1000
350K*
C&A
Analog
Air
10
diffuser
100Pa1Pa
RTD 18
PM
PT
SOS 19
TM
TC
Type-
1400K
0.5
10
0.4Mpa
C&A
Analog
Air
2
diffuser
20
PM
PT
SG/
0.4Mpa
0.1
1000
350K*
C&A
Analog
Air
2
After cooler inlet
350K
0.5
10
0.4Mpa
C&A
Analog
Air
2
After cooler
SOS 21
TM
RTD
--
outlet
151
Sl.
Type of
Type
Sensing
No
Measurement
of
element
Range
Accuracy
B.W
Subjected
Monitor (M)/
(%F.S.)
(Hz)
conditions
Control ( C)/
Temp (K)/
Aero data (A)
sensor
Interface
Medium
Qty
Location
Cooling water circuit inlet & outlet (Nozzle) Cooling water circuit inlet & outlet (HSV’s, pipe line, SC, MIM, diffuser, CD ) Cooling water circuit outlet (Nozzle) Cooling water circuit outlet (HSV’s, pipe line, SC, MIM, diffuser, CD ) Hydraulic line
Pressure (Mpa) / Shock (g)/ flow rate (kg/sec) 22
PM
PT
23
PM
PT
SG/
2 Mpa
0.5
10
350K
M&C
Analog
water
2
0.4Mpa
0.5
10
350K
M
Analog
water
28
M&C
Analog
water
1
SOS SG/ SOS
24
TM
RTD
--
350K
0.5
10
2 MPa
25
TM
RTD
--
350K
0.5
10
0.4 MPa
M
Analog
water
14
26
PM
PT
SG/
10MPa
0.1
10
350K
C
Analog
Oil
1
27
PM
PT
X
0.1
10
350K
C
Analog
Oil
2
SOS SG/
pressure ( PRV) Hydraulic line
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)/
Aero data (A)
sensor
Interface
Medium
Qty
Location
Cooling water circuit inlet & outlet (Nozzle) Cooling water circuit inlet & outlet (HSV’s, pipe line, SC, MIM, diffuser, CD ) Cooling water circuit outlet (Nozzle) Cooling water circuit outlet (HSV’s, pipe line, SC, MIM, diffuser, CD ) Hydraulic line
Remarks
Pressure (Mpa) / Shock (g)/ flow rate (kg/sec) 22
PM
PT
23
PM
PT
SG/
2 Mpa
0.5
10
350K
M&C
Analog
water
2
0.4Mpa
0.5
10
350K
M
Analog
water
28
M&C
Analog
water
1
SOS SG/ SOS
24
TM
RTD
--
350K
0.5
10
2 MPa
25
TM
RTD
--
350K
0.5
10
0.4 MPa
M
Analog
water
14
26
PM
PT
SG/
10MPa
0.1
10
350K
C
Analog
Oil
1
27
PM
PT
X
0.1
10
350K
C
Analog
Oil
2
SOS
pressure ( PRV)
SG/
Hydraulic line
SOS
pressure (HSV, MIM)
28
Water Level
29
TM
X
X
X
0.5
10
RTD
--
350K
0.5
10
350K X
C
X
water
1
C
X
X
1
Over head tank water Water temperature
Note: X - to be decided. * - Suitable adaptor is to be designed by the contractor for reducing the temperature effect from stagnation temperature temperature to ambient temperature. temperature. If not, sensor capable of withstanding withstanding stagnation temperature are to be selected. 152
Table Table 5.7 5.7:: Channel Channel type indicates requirement requirement of ot her components of instrumentation instrumentation system S.No S.No Channel Type Other comp onent s requir ed 1
Analog input
signal conditioner + analog input module + ADC
2
Analog output
DAC + analog output module
3
Digital input
Digital input module
4
Digital output
Digital output module
Table Table 5.8 5.8:: Broad specification s of signal cond itioner A)
Bu il t-i n Curr Cu rr ent and Voltag Vol tag e Exc it ati on Programmable Voltage Excitation • Programmable voltage excitation up to 15 Volts with mV resolution • Excitation voltage accuracy - 0.05% or better. Programmable ON/OFF and local or remote sense • Programmable
Table Table 5.7 5.7:: Channel Channel type indicates requirement requirement of ot her components of instrumentation instrumentation system S.No S.No Channel Type Other comp onent s requir ed 1
Analog input
signal conditioner + analog input module + ADC
2
Analog output
DAC + analog output module
3
Digital input
Digital input module
4
Digital output
Digital output module
Table Table 5.8 5.8:: Broad specification s of signal cond itioner A)
B)
C)
D)
Bu il t-i n Curr Cu rr ent and Voltag Vol tag e Exc it ati on Programmable Voltage Excitation • Programmable voltage excitation up to 15 Volts with mV resolution • Excitation voltage accuracy - 0.05% or better. Programmable ON/OFF and local or remote sense • Programmable • Current – 50mA or better • Short circuit protection should be available. available. Programmable Current Excitation (option to be chosen for applicable sensors) • Programmable Programmable current excitation up to 50 mA mA with μ A resolution Programmable ON/OFF • Programmable • Supports 2 wire/3wire/4-wire wire/3wire/4-wire RTD. • Compliance voltage- 15V minimum Inputs • Input coupling: DC • Input Impedance – 50MΩ minimum • Input Protection Protection - ±50 Volts differential, ±300 Volts Volts common mode or better • Configuration Configuration -2 to 10 wire plus plus shield; shield; input (2), excitation excitation (2), sense (2) (2) and shunt calibration (4). • Support strain gauge type of full bridge bridge sensors, sensors, piezo-resistiv piezo-resistive e pressure pressure sensors, RTD, Thermocouple. Thermocouple. Built-in Amplif ier • Amplifier range - ±2mV to ±10V • Programmable Programmable Gain Gain – 1 to 5000, ±0.05% ±0.05% accuracy accuracy or better • Dual, buffered ±10V Outputs per channel, independently selectable as filtered or Wideband • Common Mode Rejection Ratio – 120dB or better • Slew rate – 5V/µs or better • Gain Stability Stability - ±0.02% for 30 days or better, Temperature coefficient must be ±0.005% or better Linearity - ±0.01% for gains upto upto 1000, 1000, ±0.02% for higher higher gains or better • Gain Linearity • Amplifier Zero must be automatic, ±2 μV RTI or ±1.0 mV RTO or better • Zero Stability must be ± 5 μV RTI, ±1mV RTO at constant temperature, ±1 μV RTI, ±0.2 mV RTO/°C or better • Noise – must be 2.0 μV RTI plus 0.3 mV RTO, RMS or better Filter Continuously Continuously programmable programmable low pass filter, four/six pole, Bessel/ Butterworth 153
E)
F)
G)
H)
(24dB/octave) (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 Facilit Facilit y Measureme Measurements: nts: KHz • Steady pressure using Individual pressure transducer- 1 KHz • Temperature using RTD, Thermocouple -1 KHz Filter cut-off (-3dB) must be selectable at any point between the • specified range with fine resolution. Isolation Isolation should be available between the following • Sensor input and excitation • Differential Sensor input to signal output • Sensor input to output ground • Sensor input to AC power line • Input ground to output ground • Guard shield to output ground Calibration • Shunt calibrationcalibration- Programmable Programmable selection selection of shunt shunt resistors resistors in two steps steps (minimum) with 0.01% (or) programmable 16-bit DAC shunt • Automatic zero Calibration- & gain calibration • Voltage substitution for gain calibration calibration Software • Windows based software for setup and operation • Storing & retrieving retrieving of previously previously programmed programmed configuration configuration files. Automatically Automatically loading of latest programmed programmed configuration configuration file during during power-up power-up and by software issued Reset. Report generation of programmed configuration settings Others • Must be scalable up to 100+ channels on requirement • Ethernet Interface Interface or suitable interface for for programming programming the signal conditioners conditioners from 50meter distance • LED indication about the status of signal conditioning system • Input– 230 VAC ± 10%. Frequency - 50Hz ± 3%. • Temperature – Operating - 00C to 500C, Storage- -200C to 700C; Humidity95% NC
Table 5.9: List of deliverables Sr. no.
Item
Qty.
1
MIM Control System
1 set
2
Tunnel Master Control System
1 set
3
Data acquisition system for model parameters ( low
1 set
154
speed & high speed) and facility parameters 4
Health Monitoring system
1 set
5
Work station PC’s (Latest configuration)
10 No’s.
6
Sensors for facility measurements
107
7
Signal Conditioners
As per configuration*
8
Interpersonal wire less hands free communication system
1 set
9
Cables, Conduits, patch panels, instrument racks
As per configuration*
10
Constant voltage sources & current sources
As per configuration*
11
Control room equipments
As per configuration*
12
Software (Licensed)
1 set
13
UPS
2
14
Data storage unit
1
15
Surveillance camera
7
Note: ‘ * ’ – quantity shall be finalized based on detail design
155
An nex ur e
SEQUENCE OF OPERATION OF THE TUNNEL I. PRE TEST CHECKS: 1. Energize the sensors 20 minutes prior to the test– Confirm & Feedback 2. Required Pressure and Volume is achieved in the storage cylinders – Feedback 3. Required Temperature is reached in the heater – Feed back 4. Required Pressure is attained in the Horton Sphere– Feedback 5. Completed model instrumentation and measurement integrity checks – Confirm 6. Functional check of MIM system – Feedback 7. Functional check of PRV – Feedback 8. Test section door closure – Feedback 9. Functional check of schlieren system – Feedback 10. Functional check of ON/OFF valves – Feedback 11. Valve’s EGV4 to EGV7, PRV1 to PRV 3, HSV1 to HSV 8, VIV are in closed positionFeedback 12. Valve’s MBV1, MBV2, MBV3 are in open position- Feedback 13. Over head tank water level - Ensure 14. Circulating of water at predefined flow rate to all required locations -Confirm
II. TEST STARTING & RUNNING SEQUENCE: 1. Admit water at pre-defined flow rate to the following sections. Ensure for the same
•Pipe segment between heater & settling chamber. •Hot shut valves •Nozzle Throat •Model, Balance and Model Support •Diffuser segments • After cooler. Note: Don’t change the water flow rate until test is over, to ensure that wind on & wind off data belongs to pure aerodynamic data and not corrupted by additional cooling water mass- applicable for force measurement tests only. 2. Operate MIM system during wind off condition. Record the tare values of model bound sensors while sweep- applicable for force measurement tests only. 3. Check whether model is at safe position – Feedback 156
4. Open the valve VIV and mechanically latch it - Feedback 5. Open the valve’s HSV7/ 8, HSV1/3, EGV5/6/7, EGV4 in sequence- Feedback 6. Open PRV1 (or PRV 2 or PRV 3 as per mass flow requirement) 5% and allow hot air to pass through HSV7/8 for few seconds to ensure dust particles are exhausted if present. 7. Close the valve HSV7/8 and allow pressure to build up in space above pebble bed in heater. Monitor the heater pressure at the up stream of HSV7/8. 8. Check for the condition as “heater pressure ≥ desired pressure”. 9. If the step 8 is satisfied, start acquiring the data of facility parameters at predefined sampling rate and simultaneously switch on video recording. 10. Open the valve HSV2/4 - Feedback 11. Operate the PRV by considering settling chamber pressure (P0) as a feedback signal. 12. Check for the following conditions. a. Steady state error ≤ 1% of set value. b. PRV opening position less than 90%. 13. If the step 12(a) is satisfied in the pre-defined elapsed time and step 12(b) is satisfied then go to step 14 else go to step 24. 14. Monitor settling chamber pressure, settling chamber temperature and nozzle exit pressure. 15. Check for the Mach number establishment in the test section. 16. If the step 15 satisfied, a) give signal to model injection system to inject the model and b) simultaneously start acquisition of model bound parameters transient data at predefined sampling rate. Continue the transient data acquisition until the transients settle down over the model. Note: step 16(b) is to be executed only for force measurement tests. 17. Check for the condition as α=0 ± 0.05 deg. 18. If the step 17 satisfied then a) start the data acquisition of model bound parameters at pre-defined sampling rate b) start the count down timer with the pre-defined value c) activate the model incidence mechanism and d) perform the sweep operation as per the pre-defined sequence. 19. Continuously monitor the test section parameters (pressure, temperature) and timer values. Check for the following conditions. A) Parametric conditions are satisfied while sweep operation B) Model sweep operation is over when the timer indicates zero value. If both are satisfied, go to step 21 else go to step 20.
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III. TEST STOPING SEQUENCE: 20. Abort the model incidence system sequence. Issue the command to bring the model into tunnel axis ( α =00). Model should come back to the tunnel axis with in the pre-defined time. If it is satisfied, then go to step 21. If not, go to step 22. 21. Activate model injection system for with drawing of model into tunnel off-axis. Ensure that the model is at safe location and go to step 23. 22. Bring the model into tunnel off-axis by manual override. Ensure that the model is at safe location and go to step 23. 23. Stop the data acquisition of model bound parameters. 24. Close the valve EGV4 – Ensure 25. Video Recording OFF. 26. Close the valve EGV5/6/7. 27. Close the valve HSV2/4 – Ensure 28. Open the valve HSV7/8 for let out of trapped air to atmosphere. 29. Close the valve HSV7/8 when heater pressure reaches ambient. 30. Close PRV1/2/3 31. Close HSV1/3 32. Close the valve VIV. 33. Close the cooling water pipe lines after ensuring the segments are sufficiently close to desired temperature level. 34. Stop the data acquisition of tunnel parameters.
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