REQUEST FOR QUOTATION FORREPLACEMENTOF THERMAL DATA ACQUISITION AND CONTROL SYSTEM OF 6.5M CATVAC

NOMENCLATURES

SL.NO
01 / AC/DC / Alternate Current/Direct Current
02 / ACAD / Auto-Cad
03 / AMSC / Annual Maintenance Service Contract
04 / ASCII / American Standard Code For Information Interchange
05 / BPS / Bits per second.
06 / CATVAC / Comprehensive Assembly And Test Thermovac Chamber
07 / CJC / Cold Junction Compensation
08 / CMMR / Common Mode Rejection Ratio
09 / CPU / Central Processing Unit
10 / DAS / Data Acquisition System
11 / DPU / Data Processing Unit
12 / ETF / Environmental Test Facility
13 / FC / Fault Clear
14 / IPV6 / Internet Protocol Version 6
15 / ISAC / ISRO Satellite Centre
16 / ISITE / ISRO Satellite Integration And Testing Establishment
17 / ISPD / ISRO Software Process Document
18 / LCD / Liquid Crystal Display
19 / LSSC / Large Space Simulation Chamber
20 / OL / Over Load
21 / OS / Operating Systems
22 / OT / Over Temperature
23 / OV / Over Voltage
24 / PACU / Power And Control Unit
25 / PATC / Programmable Automatic temperature Controller
26 / PF / Power Supply Fault
27 / PID / Proportional Integral Differential
28 / PID no. / Parameter Identification number
29 / PRT / Platinum Resistance Thermometer
30 / PSPU / Power Signal Processing Unit
31 / RDBMS / Relational Data Base Management Systems
32 / RFP / Request For Proposal
33 / RFQ / Request For Quotation
34 / RM/LM / Remote Mode/Local Mode
35 / SCADA / Supervisory Control And Data Acquisition
36 / SGCO / Spacecraft Ground Checkout
37 / SMPS / Switching Mode Power Supplies
38 / SWG/AWG / Standard Wire Gauge/American Wire Gauge
39 / T/C / Thermocouple
40 / TCP/IP / Transmit ion Control Protocol/Internet Protocol
41 / TDACS / Thermal Data Acquisition And Control System
42 / TSG / Thermal System Group
43 / TSPU / Temperature Signal Processing Unit
44 / TVAC / Thermal Vacuum Chamber
45 / USB / Universal Serial Board

CONTENTS

Sl.No / Headings/Sub Headings / Page
Introduction / 5
Scope Of Work / 6
Supplier’s Experience & Offer Evaluation Approach / 6
Over All System Configuration / 7
System Design / 8
TSPU / 8
PSPU / 9
SMPS / 10
DPU- General / 12
DPU Software / 14
Security And Access Control / 29
Networking/ All The Hardware And Accessories Involved Including Computer / 29
Electrical Cabling / 29
Environment / 30
Design Review / 30
Pre-Delivery inspection and testing at vendor site / 30
Installation, commissioning & acceptance testing at ISAC/ISRO / 31
Training / 32
Deliverable Documents / 32
Tentative Delivery Schedule / 33
Warranty / 33
Instruction To Vendors For Submitting Offer / 33
Format For Commercial Bid / 35
Annexure A:Details of thermal simulation / thermal instrumentation on spacecraft/ electronics packages for conducting thermal tests / 38
Annexure-B: Specifications For DPU Hardware / 39
Annexure C: DPU Block Diagram / 47
Annexure D: Floor Area For TDACS / 48

INTRODUCTION

ISAC is the lead center of ISRO for the development, manufacturing, and testing of satellite in India. Several test facilities have been established to carry out the qualification / acceptance tests on satellite hardware /sub-assemblies. One of the facility,called,6.5 meter diameter Thermovac chamber (commonly known as “CATVAC”) is available at its ISITE Facility”,Marathahalli campus in Bangalore- 560037, Karnataka, India. It is equipped with a TDACSfor thermal simulation on satellite and its subsystems / sub-assemblies to conduct following tests:

  • Thermovac performance test
  • Thermal balance tests

Details of thermal simulation / thermal instrumentation for these tests are given in Annexure-A.

The TDACS of this facility was procured in 2004 and now, it is planned to replace the existing computer based data acquisition and control system, with latest technology basedTDACS and augmentation with more thermal monitoring and control equipments.

The major functionsof the proposed “Thermal Data Acquisition and Control System” is

  • To monitor temperature using different type of temperature sensors like T type Thermocouple (T/C), Platinum Resistance Thermometer (PRT) and Thermistors.
  • Acquisition of Data- satellite telemetry fromSatellite Ground Checkout (SGCO) computer system.
  • Acquisition of Data -chamber parameters from CATVAC Server through Ethernet.
  • To monitor power supplies / control parameters
  • Pseudochannel processing.
  • Control of predefined voltage, power, temperature parameter/ profile.
  • Temperature / temperature profile control using PID based auto temperature controller with any of the monitored parameter as feedback for control purpose.
  • Data processing, acquiring, storing, real time as well historical data display in specified formats, stored data retrieval, documentation etc.

On behalf of ISRO, ISAC invites the proposal from reputed and experienced vendors for “TDACS”OF 6.5M CATVACas per the following requirements / specifications provided in the subsequent section of this RFQ.

  1. Scope Of Work

Design, fabricate, pre-delivery acceptance, performance demonstration, supply, installation,commissioning and final acceptance performance testing as per specifications of total system at ISITE, ISAC,Marathahalli campus, Bangalore- 560037, Karnataka, India.

2.Supplier’s Experience & Offer Evaluation Approach

i)The vendor shall be a manufacturer or authorized integrator of the similar type of system.

ii)In case of system integrator, vendor shall hold full responsibility of execution of this system completely in all aspects and for the further maintenance. Valid authorization letters from the original manufacturer shall accompany the quotation. This shall also include the warranty support.

iii)Vendor shall provide assurance for supply of spares of the system for the minimum period of 10 years from the date of commissioning.

iv)Vendor shall have developed, installed, commissioned and managed similar type of system having value of similar scale in the last 5 years. Copy of the purchase order, work order and completion certificate of the same shall accompany the quotation.

v)Vendor shall submit list of customers with contact name, address, phone details etc. to whom similar type of system has been supplied.

vi)The vendor shall provide detailed point by point compliance of the quoted item with respect to RFQ specifications. Otherwise offer will not be considered.

vii)In case of any deviation from specification or any improvement in parameters/facility features vendor shall clearly provide justification of the same

viii)Vendor shall submit, along with offer, the necessary technical details and all relevant documents to substantiate their experiences, test and evaluation capabilities along with associated infrastructure details.

ix)Offers received will be evaluated based on merit, content of each offer, experience of vendor, and heritage of facility.

x)Vendor/s may be asked to make a detailed presentation on their offer to the expert committee of ISAC/ISRO at ISAC/ISRO as a part of vendor evaluation process. Vendor shall provide confirmation for this detailed technical presentation in the technical offer / quotation.

xi)Offers without the above information or offers with incomplete / inaccurate / false information will be rejected.

xii)ISAC/ ISROreserve the right to modify and finalize the configuration after studying the proposals from vendor.

xiii)Vendor can visit existing TDACS at ISAC/ISRO before submitting the quotation.

  1. Over all System Configuration

A typical block diagram of the system is shown in Fig-1. System shall beconfigured intofour major subsystems.

(i)TSPU

(ii)PSPU

(iii)SMPS

(iv)DPU

FIG 1: Block diagram of proposed TDAC

  1. System design:

Vendorshall design the system to cater the following minimum requirements.

4.1Storage capacity for minimum of 10TB withfull capacity redundancy.

4.2System operation24*7.

4.3Systemshall be designed to enable signal acquisition of 400 channels within 4 seconds or less and storage interval of 1 minute minimum.

4.4The systemshall be capable of restartingwithin 10 minutes after any unintentional system shutdown.

4.5Vendor shall carry out minor modification during development, testing and commissioning of the system, if required for better functioning and visualization of the system. Even after completion of project, during warranty period,whenever required, vendor shall make minor modification.

5TSPU

TSPUsshall acquirethe output signals of three types of temperature sensors, namely, T-type T/C, PRT and thermistors and process them into engineering unit.

5.1Number of TSPU units : Twoindependent units

5.2Type of temperature sensors to be processed:

5.2.1T/C: T-type

  1. Number of Channels perTSPU: 256 nos.
  2. Each T/C input cardshall have 8/16/32 channels
  3. Temperature measurement range: -200 ºC to +200 ºC
  4. Resolution of measurement: better than 0.1 ºC.
  5. Accuracy of measurement: Better than ±0.5 ºC above -40 ºC and better than ±1 ºC below – 40 ºC, including CJC and engineering unit conversion but excluding thermocouple error.
  6. The measurement accuracy and stability shall not change beyond specification for T/C after including the shielded extension wires from chamber wall exposed to noise of frequency 50 Hz and its harmonics, 10m of shielded 10m of unshielded T/C wires exposed to noise of frequency 10MHz to 40GHz.

5.2.2 PRT

  1. Number of Channels per TSPU: 16 nos.
  2. PRT Resistance at 0ºC: 100 Ohms, 300 Ohms, 1000 Ohms, 2000 Ohms (user selectable).
  3. Temperature range: -200 ºC to +200 ºC

d.Resolution: Better than0.1 ºC.

  1. Accuracy: Better than ±0.5 ºC excluding PRT error
  2. Thermistors:
  1. Number of Channels per TSPU: 48 nos.
  2. Resistance at 25ºC: 5K Ohms and 10K Ohms (user selectable).
  3. Number of Channels: 48 nos.
  4. Temperature range: -80 ºC to +150 ºC
  5. Resolution of measurement: better than 0.1 ºC.
  6. Accuracy of measurement: better than ±0.5 ºC excluding thermistors error.

5

5.1

5.2

5.3 Channel repeatability and channel to channel variation shall be within 0.2 ºCforall temperature sensors of same type.

5.4Signal conditioning shall be designed in such a way that it shall be able to accept 2 wires for T-type Thermocouple, 4 wiresfor PRT and 2 wires for thermistors.

5.5CMMR shall be greater than 100 dB.

5.6 Sampling and scan rate shall be designed to enable signal acquisition of 400 channels within 4 seconds or less.

5.7Scan interval shall be programmable in steps of 1 second.

5.8The channelsfor scanning shall be programmable with channels skip option.

5.9Each signal conditioning cardshall have a built-in auto calibration facility.

5.10 Each signal conditioning card shall have built-in open thermocouple detection circuit.

5.11 There shallbe provision for screw mount type terminal in each TSPU to interface 256 channels of Teflon insulated T/Cextension wire of 26 SWG, 48 channels of thermistors extension lines of 22 SWG, and 16 Channel of PRT extension lines of 22SWG.

5.12 The communication interfacebetween TSPU, PSPU, DPU shall be Ethernet based 10/100/1000bps.

5.13 The CJC data shall be available to main computer of DPU.

5.14All software interfaces including device drivers and I/O libraries between TSPU and DPU are to be supplied.

  1. PSPU

PSPUis aninterface unit in between SMPSand DPU. It processes and communicates the control signal from DPU to SMPS and all the monitoring signalsof SMPS to DPU.

6.1There shall be two independent units of PSPU.

6.2Each PSPU shall be capable of processing 256 channels.

6.3Each PSPU shall have two CPU for hot redundancy.

6.4Health monitoring signals of the PSPU’S mainframe shall be available to the main computer of DPU.

6.5 Provisions for simultaneous opening/closing of output relay of all/selected power supplies shall be provided.

6.6 Each PSPU/TDACS shall be capable of operating 256 numbers of SMPS in following modes

Open loop voltage and power control

Closed loop Temperature Control using PID controller with user selectable process variable from either TSPU, SGCO and CATVAC temperature parameters.

6.6SMPS shall be possible to switch from remote to local mode and local to remote mode from all workstations.

  1. SMPS

6

7

7.1 Number of Power Supplies:176 numbers.

7.2Power Output Rating:128 nos. of 0-60V / 0-12A

48 nos of 0-60V / 0-25A .

7.3Continuously variable output voltage from 0 to 60 V by means of front panel multiturn pot/ rotary pulse type knob in manual mode and using digital control input in remote mode.

7.4 Drift/stability: < 0.25% of set voltage over 24 hours.

7.5 Load regulation Voltage: 0.2%

7.6 Line regulation Voltage: < 0.2%

7.7 Ripple: < 100mV (0 to 30V), < 200mV (30V to 60V)

7.8 DC Efficiency: Better than 85%

7.9 Protection features

  1. Input through a toggle switch with protection fuse.
  2. Startup current: must meet startup current of the load. Cold start load shall less than 2 ohms.
  3. Crowbar Protection for output over-voltage: Trip voltage adjustable from 0 V (crowbar setting) to maximum output remotely from workstations and locally from front panel.
  4. Overload: Adjustable from 0 to maximum output load remotely from workstations and locally from front panel.
  5. Over temperature: Output shall automatically trip to zero on over temperature when heat sink/transformer temperature or any specific point as per the design exceeds safe temperature.
  6. The power supply should go into CC mode when overloaded. When the duration of overload is more than fixed duration which is pre definable from 0.5 seconds to 10 seconds the power supply should trip with over load indication.
  7. Power failure protection: If AC power input to power supplies goes off its output voltage will become zero and when AC power is restored the output relay shall go off.
  8. Line filter at input of each power supply shall be provided.
  1. SMPS shall be of reputed makes-LAMBDA /SORENSEN / AMETEK or from any reputed international vendor.
  2. Indications
  1. Input supply
  2. Fault indication for OV, OL and OT.
  3. Output relay ON/OFF status
  4. Operating mode- LM or RM
  1. Digital meter on front panel for output voltage measurement with 1V resolution

and current with0.25A resolution or better .

7.13Power supply output ON/OFF and RESET switch shall be available remotely and locally from front panel.

7.14 Power supply remote Control should be 12 bit or better

7.15Monitoring signals

  • Power supply status: Over voltage, Over Current, Over Temperature, Fault, Relay ON/OFF and Remote/Local.
  • Output Voltage: 12 bit or better read back signal proportional to output voltage. Accuracy better than 0.5% of reading.
  • Output Current: 12 bit or better read back signal proportional to output current. Accuracy better than 1.0% of reading.
  • Active Power:Shall be better than 0.98 at nominal input and full load condition and 0.9 at 25% of the full load.
  1. All monitoring signals shall be available at main computer.
  2. Control modes of each SMPS:
  • Open loop

-Power/voltage control.

-Voltage/power Profile mode

  • Closed loop

- Temperature control mode using PID controller algorithm. The PVshall have redundancy for closed loop temperature control. The PV can be from SGCO or TSPU or facility.

-The PID Temperature Control accuracy of +/- 0.5 Deg C. The PID controller algorithms shall have proven heritage. Vendor has to demonstrate PID controller performance in auto and manual tuning mode under thermo vacuum test conditions before integrating it to the system.(ref :fig 1)

-Predefined Time VS Temperature profile

7.18Communication/control interfaces shall be mainly RS232/485.Additional LAN interface for selected power supplies shall be provided.

7.19Forced air flow shall be from front to rear. No ventilation holes at the top or

Bottom of the chassis; Variable fan speed is required.

7.20Dimension : Width: ≈450mm, Height: ≈44mm, Depth: ≈500mm

7.21Weight : less than 15kg

  1. DPU- General

8.1 It shall acquire, store, display all the testdata parameters - historical as well in real time.

8.2It shall have modules for data analysis, data retrieval, report generation etc.

8.3It shall communicate with TSPU, PACU, SGCO computer server & facility server through Ethernet

8.4The SCADA application software shall be compatible to the DPU, TSPU, PACU hardware, SGCO/Facility Gateway etc. The application software shall have standard protocol to connect DPU, TSPU, PACU and Gateway.

8.5The DPU hardware shall consist of rack and rack mountable Main and Backup servers,Web Server, External Storage, Backup storage devices, Network devices, Work stations, computer peripherals and wall mountable LCD display screens etc.

8.6All the servers shall have common hardware configuration and shall be interchangeable.

8.7System image of each completely configured server shall be available on bootable media to ascertain bare metal recovery. These system images will be useful in system recovery to a fully operationalconfiguration after disk crash or corruption.

8.8The following are the minimum requirement of computers and its peripherals:

  1. Main Server: One Number
  2. Redundant Server: One Number
  3. Web server: one number
  4. Work stations: 10 No’s
  5. Data Backup storage device – 2 No’s
  6. Black & White Printers( A4 size, duplex printing facility): two Numbers
  7. Color laser Printer ( A4 size, duplex printing facility): one Number
  8. Scanners: One Number
  9. Wall mountable Display screens: 3 nos.
  10. External Storage – 3 Numbers
  11. Switch: L2, L2+ as required
  12. Servers, workstations, external storage etc. shall have configuration as specifiedin annexure Bor better to meet the application software requirement.
  13. Thereshall not have single point failure.
  14. Web server shall be able to handle at least 25 simultaneous client connections.
  15. Desktops shall not to be quoted in place of Workstations
  16. Latest version of MS- Office (For test data documentation)– License- 2Nos,ACAD (for animation and test data documentation) – License – 2 No’sshall be provided.

8

9DPU Software

ISPD Standards and guidelines shall be followed for Software development. These standards/guidelines are available with ISAC/ISRO and will be providedto supplier by ISAC/ISRO.

Source code written specific to ISAC shall be provided as deliverable item to ISAC.

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9

9.1Support Platform

Server: Red Hat Enterprise(version 7.0 or above) Linux

Client: Linux (version 7.0 or above)/ Windows8.1 professional version or

Higher)

The vendor shall chose programming languages which support standard Internet browsers like IE, Mozilla Fire Fox, Google chrome to meet the requirements specified in this document and the languages shall take-care future upgradeability.

  • Vendor shall provide all required software licenses.
  • Vendor shall provide the driver software for all printers, scanners and any other hardware
  • Scalable configuration:

The application software shall be configurable for the following

  • Single user System using Standalone Workstation.Vendor to plan the solution such that workstations with local disk can be used in place of servers with external storageby installing required OS, RDBMS, application software on the local system. Reduced performance acceptable in this scenario. The same to be demonstrated at the site.
  • Multi-user system using Client/Server Configuration.

9.3 RDBMS software: The query language used by the application software to log and retrieve data must be able to support multipleRDBMSlike ORACLE, MySQL etc.

The application software shall have the following options to take care of the computer hardware configuration:

RDBMS in external storage

Or

RDBMS in local hard disk of servers (Main, Redundant and web Servers) with provision for replication of data on both Main and Backup server for redundancy.

Without RDBMS: In such case, data storage option using flat files in suitable format shall be provided. This data will be analyzed separately by opening the file in a “spread-sheet” without using the application software. Provision shall exist to split the file into user defined file size.