SPECIFICATION

Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)

Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
1


INTEGRATED AEROSTAT SURVEILLANCE SYSTEM-MEDIUM SIZE
(NAKSHATRA)

SPECIFICATION OF
WINCH AND MOORING SYSTEM










AERIAL DELIVERY RESEARCH & DEVELOPMENT ESTABLISHMENT
DEFENCE RESEARCH & DEVELOPMENT ORGANISATION
MINISTRY OF DEFENCE, GOVERNMENT OF INDIA
P. B NO. 51, STATION ROAD, AGRA CANTT 282 001



Information in this document is property of Aerial Delivery Research & Development
Establishment. Unless otherwise specified, no part of this document may be reproduced or utilized
in any form or by any means, electronic or mechanical, including photocopying and microfilm,
without permission in writing from Director, Aerial Delivery Research & Development
Establishment, Agra.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
2


TABLE OF CONTENTS


Chapter No. Chapter name Page no.
1.0 Introduction 3
2.0 System Description 7
3.0 System Specification/Requirements 11
4.0 Subsystem Description 21
5.0 Scope of work 58
6.0 Inspection and Acceptance Procedures 59
7.0 Painting 59
8.0 Integration, Installation and commissioning 60
9.0
Materials for
Fabrication/integration/installation
60
10.0 Quality control 61
11.0 Perfection of work 62
12.0 Safety requirements 63
13.0 Tools for maintenance 64
14.0 Jigs and fixtures 64
15.0 Deliverables 64
16.0 Time schedule 65
17.0 Guarantee/Warranty 66
18.0 Product Support 66
19.0 Presentation 66
20.0 Compliance sheet 66




SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
3

1.0 Introduction

Winching and Mooring system is one of the major subsystems of an
Aerostat. It has two parts, one is winch, which is required for raising, lowering
& holding the balloon at a desired height, Second a mooring system on which
the balloon is anchored when not in flight. The system is required to be
fabricated for medium size of Aerostat. Mooring system must have freedom of
wind-vaning.

This system consists of a winch system, which is required for hoisting
& de-hosting of the aerostat under controlled conditions, to a desired attitude
and/or making necessary operational adjustments to the aerostat at different
altitude during flight. Mooring System is used to moor the aerostat at ground
in case of high wind conditions or maintenance / integration purpose. Mooring
is an important stage of the aerostat launch program. For the integration of
the equipment on the balloon, its maintenance and several other reasons,
aerostat needs to be brought down on the ground and moored in such a way
so as the stresses on the aerostat structure are minimal in the moored
condition.

The complete system has to be mounted on the trailer through the
slewing bearing. This slewing bearing will provide the wind vaning of the
system. However trailer will provide the relocatibility of the system. The trailer
should be provided keeping in the view that it should be compatible with the
TATA LPS 4018.

The configuration of this system is shown at figure no 1 in Deployed
condition and figure no 2 in transportable condition. The winch and mooring
system with balloon in moored condition and with flying condition is shown in
the figure 3 & 4 respectively.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
4


















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


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
5





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


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
6



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


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
7

2.0 System Description

The winch and mooring system provides platform to hold the balloon
for the fitment of the payload to it and maintenance requirements of the
Aerostat. It is also used for launching and recovery of the balloon. The
winching system is used for inhauling and outhauling of the balloon at
required height with required speed. The various subsystems of the winch and
mooring system are shown in the system tree (figure no 05) and in the
pictorial view in figure no. 06 & 07. One similar winch and mooring system is
available with ADRDE. All the parts have been assembled together to form a
single unit from which aerostat launch, recovery, mooring, maintenance and
controlling can be done. The mooring tower along with boom, winch enclosure
and flying sheave rotates about the vertical axis passing through the center of
the main bearing. A Double capstan type hydraulic winch system is chosen for
the above configuration with spooler for uniform winding of tether. A hard
nose with nose probe and a latch assembly is chosen for mooring system.
The entire winch and mooring system will be mounted on the trailer to make
the system relocatable i.e. it will be transportable in a stowed condition. This
will be achieved by incorporating folding side arms for the close haul winches
and a foldable tower for the cradle and latch assembly. The winch assembly
and hydraulic power pack are enclosed inside a shelter (enclosure), which is
mounted over the boom. This enclose is an air-conditioned chamber. The
prime mover for towing the trailer mounted winch and mooring system is
TATA LPS 4018.
The winch and mooring system consists of following subsystems:
I) Fabricated Structure
II) Docking and tether routing units
III) Winch assemblies
IV) Hydraulic system
V) Electrical and electronic subsystem
VI) Miscellaneous subsystem


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
8



















Figure 5: System tree


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
9



















Figure 6: Various subsystems of Winch and mooring system


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
10

Figure 7: Various subsystems of Winch and mooring system


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
11

3.0 System Specifications/Requirements:
3.1 Brief Specification:
S.
No.
Parameters Value
i Winch Type Capstan type hydraulic
ii Mooring type Hard nose type, wind vanning
iii
Dimension in transportable
condition
As per given in the figure 8
iv Relocatibility
Mounted on trailer and compatible with
TATA LPS 4018
v
Max. Winding/unwinding speed
of main tether winch
75 m/min at 34000 N
vi
Max. winding/unwinding speed of
close haul/nose line winch
30 m/min at 1500O N
vii Brake holding capacity 100000 N
viii
Max. winding/unwinding speed in
syncro mode for all winches
30 m/min
ix
Survival wind speed (when
moored)
70 knots
x
Operational wind speed (when
parked at altitude)
50 knots
xi Operation
a) Through joystick, through lever,
Manual cranking etc.
b) System should also be operated
through remote control panel by Radio
Frequency command system
xii Stow drum Storage Capacity 1500m of tether
xiii Tether
Fiber optic, power conducting, lightning
braid having diameter 180.5 mm
xiv FORJ At winch drum
xv Material Marine grade anti-corrosive steel
xvi Data logging facility Record to store the various data
xvii Storage
Rugged storage device should be
provided for storage of data for minimum
15 Days
xviii EMI/EMC
All electrical/electronic equipments must
be EMI/EMC protected
xix Portability of data
It should be possible to transfer data from
archive media into suitable removable
hard discs/CDs/zip drives etc.




SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
12





Fig 8: Loads coming on Winch and Mooring Platform
1
2
.
7

m

12.9 m
F
2

F
1

38 m
1
2
.
7

m

18.8 m
23.6 m
19.7 m
C P
C G
Confluence
Point
W
C B
F
3



SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
13





These dimensions are indicative value only the final dimension will be finalised during design review.
Figure 9: Winch and mooring system dimension in folded condition
H
e
i
g
h
t

=

4
m

Length = 14m Width = 2.5m


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
14

3.2 Detail Specification:
i) The Winch and mooring system is required to hold the medium size
Aerostat. The brief dimension of the Aerostat has been given at the
Figure no. 9.
ii) Mooring structure should be made in foldable modules to enhance
the ease in transportation. The dimension of the winch and mooring
system in the folded condition should not be more than 14 m
(length) X 2.5 m (width) X 3.7m (height). The folding/unfolding
operation should be mechanised (preferably hydraulically/electro-
mechanical). The suitable locking arrangements should be provided
during transportation and actual operational condition.
iii) The winch is required to be capstan type with level winding
arrangement (spooler) for uniform winding of tether, Single tether
with hydraulic as well as electronic control.
iv) Mooring system should be turn table type, hard nose with nose
cradle and a latch assembly. Mooring system must have freedom of
wind - vaning.
v) A pedestal hydraulic power drive is required to orient the winch and
mooring system as per the requirement of the Aerostat.
vi) The winch should be capable of hoisting and de hoisting the
Aerostat at a tether tension of 34000 N at winding speed of 75
m/min.
vii) The speed of the winch and mooring system should be varied from
0 to 75 m/min.
viii) The Nose line winch and close haul winches should be designed to
operate at 30 m/min at a load of 15000 N. However it should
withstand a load of 30000 N.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
15

ix) perating limits: The system should be capable of withstanding the
following conditions in different orientations:
(a) 70 Knots (36 m/s) wind speed when the balloon is moored on
the structure and faces into the wind.
(b) Side force corresponding to 20 knots (10.29 m/s) wind speed,
which acts in case the bearing fails to rotate.
x) Winch and mooring system is capable of withstanding 100000 N
acting at the flying sheave. The structure, flying sheave, Pulleys etc
should be design to withstand that much of load.
xi) The whole structure should able to rotate freely at a torque value
1200 Nm or less.
xii) The brake holding capacity of the winch system should be 100 kN.
It means that when this much of load will come on the tether, the
tether should not unwind itself from the winding drum.
xiii) All Aerostat program e.g. launching, recovery, mooring, controlling
etc can be done should be done at single place i.e. at the operator
cabin inside the winch enclosure. Provision should be made so that
operator can communicate with other crew members.
xiv) A provision should be made in the cradle and latch assembly for
automatic release of nose probe from the cradle.
xv) Provision should be made to digital display and record the various
parameters e.g. winding/unwinding speed of the main winch, tether
tension value before and after the capstan, tension value of the
nose line and close haul lines, Tether released out from the drum
and tether storage length, Temperature of hydraulic oil, level of the
hydraulic oil in the reservoir etc.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
16

xvi) Data logging facility should be provided to record the data for
minimum Fifteen (15) days. A rugged storage data device should be
provided along with the system.
xvii) A portable data storage and analysis device and a online rugged
data streaming device should also be provided for analysis of the
store data.
xviii) All operation should be done by joystick provided at operator cabin.
However provision should also be made to operate the system
through hydraulic lever through Proportional control valve for
redundancy. In case power failure the manual operation should also
be provided.
xix) The operator can also operate the system form the ground through
remote/operator panel, instead of sitting in the operating cabin if the
need arises. A Radio Frequency link in this regard should also be
available.
xx) Pneumatic Power Pack and airbag is controlled and operated from
the controller cabin.
xxi) The winch should be automatically stop the operation when the
seventh (7
th
) turn of the lowest layer of the tether remains on the
stow drum.
xxii) Synchronization of two close haul winches, nose line winch,
capstan and stow drum will be made. This means capstan, stow
drum, two close haul winch and nose line winch should be operated
simultaneously at same speed. The maximum winding/unwinding
speed in this case will be 30 m/min
xxiii) The winch and mooring should be suitable for inflation and deflation
of the Aerostat when moored at the mooring structure.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
17

xxiv) All the items should be used for the fabrication of the winch and
mooring system should be of flameproof & explosion proof quality.
xxv) All fasteners e.g. nuts and bolts, studs etc used in the assembly
should be of suitable strength and protection with corrosion.
xxvi) The system should be transportable by road in folded conditions.
xxvii) Access ladder should be provided to access the operator cabin and
the roof of the winch enclosure. Access ladder should have proper
side and overhead protection.
xxviii) The hydraulic oil shall be selected as per following temperature
range. Storage temperature 20
0
C to +70
0
C, Operating
temperature 10
0
C to +55
0
C
xxix) Cradle is able to tilt +125
0
and 45
0
from the horizontal
xxx) A slewing bearing of suitable capacity is to be provided which can
withstand radial, axial and tilting moments.
xxxi) Material to be used for fabrication of the structure is marine grade
anti-corrosive steel or equivalent.
xxxii) One sets of Slip rigs integrated with FORJ are provided to supply
the power to the prime mover as well as two way transfer the data
from the airborne to the ground. Such slip ring and FORJ is to be
provided at the stow drum to provide power and data to the tether.
The Power slip ring with central hole is to be provided at the
pedestal to transfer the power from the main supply to the rotating
winch and mooring system.
xxxiii) The trailer should be suitably selected/designed to house the
system. It should also be able to travel in desert terrain and
compatible with the prime mover TATA LPS 4018.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
18

xxxiv) Provision should be made to grounding the lightening braid of the
tether.
xxxv) The winch enclosure should be properly covered so that the winch
enclosure is protected from dust, rain etc. To reduce the heat load
on the air conditioner the panels of the cover should be made of
insulating material.
xxxvi) The critical components of the system should sustain the following
environmental conditions:
a) Ambient temperature
Operating temperature range: 10
0
C to +55
0
C
Storage temperature range: 20
0
C to +70
0
C
b) Humidity: up to 95% at +40
o
C, non-condensing conditions.
c) Altitude up to 3350 m from AMSL
d) Rain intensity (IS: 9000 part 16, Static pressure 100 15 kpa,
4 shower used at an angle of 45
0
for 01 hour duration).
e) Salinity (IS: 8252 part 10 Clause 4.2.2)
f) Dust as encountered in desert areas (IS: 9000 part 12,
Temperature 40 3
0
C, relative humidity 40% steam of dust
laden air , dust concentration less than 10 3 g for a duration
one hour).
g) Fungus growth as encountered in tropical climates (not
encountered in mechanical components).
xxxvii) The various input data for system are as follows*
a. Aerostat Parameters
Aerostat Volume : 3500 cum
Maximum Buoyant Force : 32570 N
Aerostat Weight : 1492 kg + 300 kg payload
Offset of Confluence Point : 12.9 m, from Nose
: 12.7 m, below from central axis
* These data are indicative only however actual value will be finalised at
the time of design review


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
19

Offset of CP : 19.7 m, from Nose
Offset of CB : 18.8 m, from Nose
Offset of CG : 23.6 m, from Nose
b. Tether Parameters
Maximum Tether Length : 1500 m
Diameter : 18 + 0.5 mm
Tether Bending Diameter (Minimum) : 0.6 m
Tether Weight : 0.4 kg/m
c. Capstan design Parameters
Maximum Tether Tension : 50000 N
Maximum Full Load Speed : 75 m/min (at 34000 N)
Brake Holding Capacity : 100000 N
d. Stow drum & Spooler Parameters
Storage capacity : 1500 m length of tether
Maximum Tether Tension : 15000 N
e. Close Haul Winch Parameters
Maximum Cable Length Handled : 60 m
Maximum Operational Speed : 30 m/min (at 15000 N)
Brake Holding Capacity : 30000 N
f. Load values
Case I: Balloon is in moored condition, Wind Direction Parallel
to balloon longitudinal Axis and blowing at a speed of 70 knots
(36 m/s), both the close haul lines are secured:
Drag and lift forces are
Wind speed
(m/sec)
Balloon Angle of attack
Drag Force
Lift Force
36 0
0
6071 N -74 N
36 +6
0
7592 N 16839 N
36 -6
0
6322 N -16706 N



SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
20

Case II: Balloon is in moored condition; Wind Direction
Parallel to balloon longitudinal Axis and blowing at a speed of 70
knots (36 m/s), one of the close haul lines snaps off.:
Case III: Balloon is in moored condition; Wind Direction
Parallel to balloon longitudinal Axis and blowing at a speed of 70
knots (36 m/s), both the close haul lines snaps off.:
Case IV: Balloon is in moored condition; Wind Direction
Parallel to balloon longitudinal Axis and blowing at a speed of 70
knots (36 m/s), nose lines snaps off.:
Case V: Balloon is in moored condition; Wind Direction
perpendicular to balloon longitudinal Axis and blowing at the
speed of 20 knots (10.29 m/s), Bearing fails and not rotating:
Case VI: Balloon is in flying condition;
Tether tension at 50 knots (25.72 m/s) wind speed: 50000 N
Case VII: Winch and mooring system is in transportation mode
and system is in collapsed condition;
Vertical Acceleration : 2g
Horizontal Acceleration : 2g, with 1g vertical acceleration
Lateral Acceleration : 1.2g, with 1g vertical acceleration
All accelerations occur exclusive to each other





SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
21


4.0 Subsystem Description:
4.1 Fabricated structure:
The fabricated structure consists of following subsystems:
I) Mooring tower
II) Boom
III) Close haul swing frame
IV) Frame skin (shelter)
V) Pedestal
VI) Trailer with outriggers

4.1.1 Mooring Tower:
Mooring Tower is required to hold and anchor the balloon at
nose with the help of cradle and latch assembly. It is made of marine
grade anti-corrosive steel. The structural design is well supported by
FEM analysis. It can be folded in transportable mode.














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


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
22

Fig. 11: boom
4.1.2 Boom:
Boom is the main platform upon which mooring tower, inflatable
trestle airbags, close haul swing frame, flying sheave, capstan, stow
drum and spooler, hydraulic power pack and other sub-systems with
winch enclosure are mounted. It is a made of marine grade anti-
corrosive steel. The design of the boom is well supported by FEM
analysis.










4.1.3 Close haul Swing frames:
Close haul swing frames one each at the port and starboard side
of the boom is to be provided to mount the close haul winches. The
frames are foldable so that it can be folded during transportation. The
design of the boom is well supported by FEM analysis.









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


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
23













Fig. 13: integrated mooring tower, boom and close haul swing frames
SPECIFICATION SHEET FOR ASTAT MOORING STRUCTURE
1. Application To mount winch system and its all accessories
2. Quantity 01 No.
3. Configuration Compact and light weight design
4. Design
Requirements
It must have one point support at slewing bearing
To mount winch system and its all accessories, one
main frame should be there (usually known as
boom).
To mount cradle, it should have mooring tower.
To mount two close haul winches, it must have two
close haul swing frames
To vary the position of close haul winches, close
haul swing frame must have locking arrangement
at a particular location
The system is transportable so mooring tower and
close haul swing frames must be foldable
All accessories to be mounted on boom in such a
way that the CG of system is very close to axis of
slewing bearing
5. Design Parameters Forces transferred from balloon to mooring structure
6. Design
methodology
Theoretical analysis supported by FEM analysis for
all four load cases (ref Para no. 3.2 (xxxvii)(f))
7. Overall Dimension For transportable condition:
Length (l): 12 m, Width (w): 2.5 m, Height (h): 3.7 m
8. Material Marine grade anti-corrosive steel or equivalent
9. Weight Minimum



SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
24

4.1.4 Frame skin (shelter):
To protect the vital tether in stored condition from environmental
condition Winch enclosure, which contain hydraulic power pack,
Capstan, stow drum etc. is covered with shelter. The winch enclosure
is air-conditioned.

4.1.5 Pedestal:
Pedestal forms an interface between trailer and rotating mooring
station. It is mounted on the trailer using bolts. The pedestal cavity
houses the slewing bearing and the system power slip ring and FORJ
assembly, which is required for two way power and data transmission.









4.1.6 Trailer:
The entire winch and mooring system is mounted on a trailer to
ease the transportation. The trailer used is of a semi low-bed
configuration with four extending outriggers, which can be attached to a
tow vehicle for relocation. The trailer should be able to travel in the
desert condition. The extended outriggers offer added stability to the
system during operation. Electrically/hydraulically operated side riggers
will be provided to secure the trailer during deployment of Aerostat.
Four (4) numbers of hooks should be provided to lift the whole system
(trailer plus winch and mooring system) through crane.

Fig. 14: Pedestal


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
25















Fig 15: Trailer

4.2 Docking and tether routing Units:
The docking unit is normally used for docking the balloon to the winch
and mooring system however the tether routing units guide the tether from the
balloon to the stow drum. The docking unit consists of following
i) Cradle assembly
ii) Flying sheave
iii) Tether Guide rollers assembly
iv) Tether Guide sheave assembly
v) High tension sensor assembly
vi) Low tension sensor assembly

4.2.1 Cradle assembly
The Cradle is mounted on the top of the Mooring tower and serves as
a docking point for the balloon Nose during launching and recovery of the
Aerostat. It is in the form of conical shape. Cradle is fitted with latching


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
26

assembly and capable of tilting +125 degree up and -45 degree down in the
vertical plane by means of a hydraulic actuator. The actuation of the hydraulic
actuator is controlled by operator sitting in the control cabin. The nose probe
is design and fabricated to suit the latch assembly for proper and easier
docking and undocking.







Fig 16: Cradle assembly
4.2.2 Flying sheave
Flying sheave is used to guide the tether coming from Aerostat to
capstan and the main winch through the set of pulleys. It consists of large
pulley that is pivoted so as to allow rotation about the two axes. It is fitted with
the counterweight. The design of flying sheave allows it to orient itself based
on Aerostat location and maintain the minimum bending diameter of the
tether.









Fig 17: Flying Sheave


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
27


4.2.3 Tether guide rollers assembly
These units help the tether to route from the flying sheave to the
capstan. These units are used where the space is not available to
mount the sheave.










Fig 18: Tether guide roller assembly
4.2.4 Tether guide sheave assembly
Tether guide sheave assembly helps to guide tether from the
flying sheave to the capstan.





Fig 19: Tether guide sheave assembly
4.2.5 High tension sensor assembly
Two tension-sensing units are used to measure the tension of
the tether. The first unit, which is called the high tension sensor
assembly is fitted between the Flying Sheave and the Capstan and


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
28

used to measure the tether tension which is on the higher tension side
of the capstan. The tension on this side ranges from 0-90000 N.








Fig 20: High tension sensor assembly
4.2.6 Low tension sensor assembly
The second unit which is called the high tension sensor assembly is
fitted between the Capstan and the spooler pulley and used to measure the
tether tension coming after the reduction of tension from the capstan. The
maximum tension experienced in this region is 6500 N.








Fig 21: Low tension sensor assembly

4.3 Winch Assemblies
Launching, recovery, in-hauling, out-hauling operation of the balloon
are carried out using the various winches. The Capstan, Stow Drum and the
Spooler are used for tether handling. Launching & recovery operation is
achieved by two Close Haul winches and the Nose Line Winch. All controls to


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
29

these winches are available to the operator at the Operator Control Desk.
Winch assembly consists of following:
i) Capstan,
ii) Stow drum with spooler,
iii) Close haul & nose line winches

4.3.1 Capstan
The function of the Capstan is to reduce the tether tension prior
to stowage on the Stow Drum, therefore preventing the tether from
getting crushed when stored in multiple layers. The Capstan consists of
two grooved drums around which the tether is wrapped prior to feeding the
stow drum. These drums are mechanically synchronized and are driven by
a single hydraulic motor via a reduction gearbox and clutch. It is primarily
driven by the hydraulic motor, the speed of which is controlled from the
Operator Control Desk. A manual drive should also be provided for
redundancy. For this shifting provision should also be given. The capstan
should be provided with integral fail-safe parking brake unit that prevents
the tether from unwinding under operational loads. The brakes are sized
for braking torque equivalent to 9000 kgf tether tension at capstan.









Fig 22: Capstan





SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
30

SPECIFICATION SHEET FOR ASTAT CAPSTAN
1. Application : Tether tension relieving prior to storage on stow drum
2. Quantity : 1 no.
3. Configuration :

Dual Cantilevered drums Vertical stacking
4. Tether Details
:
Diameter : 18+0.5 mm
Total Length : 1500 m
Tether weight :0.4 kg/m (estimated)
5. Drum
Dimensions :
Grooved Hollow Drum (Linear Grooves)
Mean Diameter at drum groove : 620 mm
No. of grooves on drum : 5
No. of layers : 1
Groove Outer Diameter : 640 650 mm
Drums to have identical construction
Drums when assembled to have half pitch groove offset
Vertical offset between drums to be minimized
6. Drum Shafts : Hollow shafts ( 2 Nos.)
7. Design
Parameters:
Maximum Tether Speed : 75 m/min
Operational Tether Tension : 34000 N
Brake Holding Tether Tension : 100000 N
8. Input Power From Hydraulic motor
9. Gearbox :

1 No. integrated gearbox
*Gearbox Efficiency > 85 % to be ensured
*Manual operation: Should function with hydraulic motor
braked
*Manual clutch engagement / disengagement
*Easy access to all manual handles from outside
*Integral Multi-disc brake units
*Brake units to be compact and optimally located


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
31

10. Features : Peripheral rollers to be provided around drums to ensure
tether does not leave groove when slack Protective cover to
be provided over drums, absence of which should not hinder
Capstan operation
Protective cover to have tether inlet and exit cut-outs
Provision for lifting lugs to lift entire Capstan unit vertically
System weight optimization to be enforced during design
All manual interfaces to be accessible from motor side
All sharp corners in path of tether to be rounded off
11. Weight: Minimum
Note : This specification sheet are for reference only.

4.3.2 Stow drum with spooler
Stow Drum and Spooler are used for tether stowage after
tension relieving at Capstan. It should have capacity to store 1500m
length of tether. The stow drum and spooler are driven using a single
hydraulic motor. It should be fitted with an integral fail-safe brake to
prevent tether unwinding when not in operation. Provision should also
be made on the stow drum for manual operation using a hand lever.
Due to increase in diameter when tether is stored in multiple layers on
the stow drum, the linear velocity of tether at stow drum and at capstan
tend to vary, leading to fluctuation in tether tension. So a
synchronization of speed between the capstan and stow drum is
required to be taken care during designing of the system. This
synchronization should be done electronically as well as the
mechanically.
The Spooler is used for level winding of tether on the Stow
Drum. This is achieved by double helix diamond screw and pawl
arrangements. The diamond screw is driven by stow drum hydraulic
motor via the gearbox. The Stow Drum is mechanically synchronized
with the Spooler for uniform tether winding on the drum. For every turn


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
32

of the drum the spooler pulley moves by 1(one) tether pitch distance
linearly. The Stow Drum can be disengaged from the spooler by
removing the coupling between them to allow manual correction to
spooler carriage location during initial tether winding on the drum or
intermittently.







Fig 23: Stow drum & spooler

SPECIFICATION SHEET FOR ASTAT STOW DRUM & SPOOLER
1. Application :
Storage of tether after tension relieving at
capstan
2. Quantity : 1 no.
3. Configuration : Perpendicular tether feed (parallel to drum axis)
4. Tether Details :
Diameter : 18+0.5 mm
Total Length : 1500 m
Tether weight : 400 g/m (estimated)
5. Drum Dimension:
Flat Drum
Diameter: 600 mm
Drum Flange Diameter : 1200 mm
Flange - Flange inner offset : Min. 1230 mm
Max. 1235 mm
Drum Slot width (for cable termination) : 45 mm
6. Drum storage Capacity 1500 m
7. Drum Shafts :
Flanged hollow shafts ( 2 Nos.)
Shaft Inner Diameters : 150 mm, each
Shaft Bolted to Drum
8. Input power From Hydraulic motor
9. Design Parameters
Maximum cable Speed:
Maximum Tension:

75 m/min (corresponding to 34000 N at Capstan)
15000 N
10. Gearbox :
1 No. integrated gearbox
*Gearbox Efficiency > 85 % to be ensured
*Manual operation: Should function with hydraulic


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
33

motor braked
*Manual clutch engagement / disengagement
*Easy access to all manual handles from outside
*Integral Multi-disc brake units
*Brake units to be compact and optimally located
11. Spooler :
*Light weight pulley with vertical axis, mounted
on carriage with Diamond Screw & Pawl
Arrangement and Hollow guide shafts (2 Nos.)
*Pulley Diameter : 600 mm
*Pulley width to cater for spooling on 1st and last
layers
12. Features:
*Protective covers to be provided where
necessary
*All sharp corners to be rounded of in tether path
*All manual operations to be possible from
spooler side
*System weight optimization to be enforced
during design

Note : This specification sheet are for reference only.

4.3.3 Close haul & nose line winches
The two Close Haul winches are used to hold the Aerostat from
the port and starboard side of the balloon. The Close Haul winches are
mounted on two swing frames that can be folded during transportation.
The construction of the Nose Line winch is identical to the close haul
winches. The Nose Line Winch is located below the mooring tower and
is used for guiding the Aerostat nose probe into the Cradle for docking
through the nose line cable. These drums should have capacity to store
80 m of mooring cable and are driven by a hydraulic motor via a
reduction gearbox. The operation of these winches is controlled from
the Operator Control Desk and they can be selectively synchronized
with all other winch. These winches are fitted with an integral fail-safe
brake that prevents winch slippage when not in operation. Provision
should be made for a manual over ride for operation using a hand
pump to drive the close haul winch motor.




SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
34





















Fig. 24: Close haul/Nose line winch

Specification Sheet For Close Haul/Nose line Winch

1. Application: Storage and handling of close haul
lines
2. Quantity: 3 nos.
3. Configuration: Compact & Light weight Design
4. Close Haul Line Details:
(ADRDE will supply)
Diameter : 12 mm
Total Length to be stowed: 80 m
Material : Nylon
5. Drum Dimension: Cylindrical Drum without grooves
Drum Diameter: 300 mm
Flange Diameter : 450 mm
Flange Slot width (for line termination) :
20 mm
6. Design Parameters
Maximum cable Speed:
Maximum Tension:
Brake load:

30 m/min
12000 N
24000 N
7. Weight: minimum

Note: These specification sheets are for reference only.



SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
35

4.4 Hydraulic System
Hydraulic system consists of
i) Electric motor
ii) Hydraulic pump
iii) Hydraulic motor and actuator,
iv) Proportional Valves Assembly
v) Oil tank
vi) Oil cooler system
vii) Various Valves & Accessories.
The hydraulic drives are required to drive capstan, stow drum, two
close haul winches, a nose line winch, tower actuator, pedestal drive and
cradle actuator. The drives to these actuators should come from a single
hydraulic power pack. This hydraulic power pack is integrated with the
proportional direction control valve and counterbalance valve. High response
shock and cavitation valve should also be incorporated to absorb high shocks
when the joystick will be released and Capstan brakes immediately.
Additionally one relief valve should be provided in every actuator circuit. The
system should be designed at Maximum system pressure 350 bar and
maximum flow of 300 lpm.
All the operation of the actuator is through Joystick & through hydraulic
lever which is placed at the control cabin. Some of the actuator like stow drum
and capstan can also be operated through manual cranking. The reference
hydraulic circuit which may be used for this operation is given in figure no.25.
The bill of material and their make is also given in table no.1. The given
circuit and bill of materials are only for the reference, the actual circuit
and bill of material fill be finalized during the design and its review and
vetted by DIRECTOR ADRDE or his authorized representative. The entire
system should be designed and configured by using high quality
Commercially Off The Shelf (COTS) equipment.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
36







SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
37

Table 1
Sl.
No.
Part description
Specification
Make
1. Electric Motor 3-, 415V, 75 kW, Qty: 2no.
Crompton Greaves
or equivalent
2. Hydraulic Pump
Variable Displacement, 100cc/rev,
HP limiter with load sensing and
pressure compensator, Qty: 2no
Rexroth or
equivalent
3. Heater 12 kW, 3-, 230 V A/C
Elmec or
Equivalent
4.
Hydraulic
Reservoir
Capacity of 1000 ltrs with access
door for cleaning
Reputed make
5. Oil level Gauge For giving information of oil level
Stauff or
equivalent
6. Level switch
For switching operation between
two oil level
Monitor India or
equivalent
7.
Temperature
sensor
Range -50
0
C to +250
0
C Wika or equivalent
8. Air breather 2m rating Argo or equivalent
9.
Direction control
valve
Various sizes
Rexroth or
equivalent
10. Check Valve

Capacity Quantity
10 lpm 03 no.
22.5 lpm 07 no.
40 lpm 04 no.
70 lpm 12 no.
120 lpm 01 no.
135 lpm 03 no.
180 lpm 01 no.
280 lpm 01 no.
Rexroth or
equivalent


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
38

11.
Pressure line
filter
12 m size filter with clog indicator Pall or equivalent
12. Return line filter 5 m size filter with clog indicator Pall or equivalent
13.
Pressure relief
Valve
Capacity Quantity
95 lpm 03 no.
320 lpm 01 no.
Rexroth or
equivalent
14.
Pressure
reducing valve
With various pressure setting and
sizes
Rexroth or
equivalent
15. Pressure Gauge Range 0 to 450 bar
Forbes Marshal or
equivalent
16.
Proportional
valve
180 lpm , 115 lpm (3 valve module)
and 180lpm (4valve module)
Rexroth or
equivalent
17. Shuttle Valve
Pressure Capacity Quantity
315 bar 30 lpm 01 no.
350 bar 10 lpm 05 no.
Rexroth or
equivalent
18.
Counterbalance
valve (Air
vented)
Capacity Quantity
60 lpm 06 no.
120 lpm 08 no.
480 lpm 02 no.
Rexroth or
equivalent
19. Shut-off valve
Input Pressure: 350 bar
Capacity: 80 lpm
Quantity: 01 no.
Rexroth or
equivalent
20. Needle Valve
Input Pressure: 350 bar
Capacity: 40 lpm
Quantity: 02 no.
Rexroth or
equivalent
21. Ball Valve Size: 1, 2, 3
Rexroth or
equivalent
22. Hydraulic Motor
625 cc/rev, 1800 rpm, Qty: 03 no.
468 cc/rev,1800 rpm, Qty: 01 no.
1130 cc/rev, 110 rpm, Qty: 01 no
2857 cc/rev, 63 rpm, Qty: 01 no
Rexroth or
equivalent


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
39

23.
Hydraulic
Cylinder
Bore Dia: 140mm
Rod Dia: 90mm
Stroke: 1150mm
Rexroth or
equivalent
24. Oil Cooler Unit Cooling capacity 45 kW
Emmegi or
equivalent
25. Rotary Actuator
Bore 50.8 mm, Rotation 120
0
, both
direction rotation
Rexroth or
equivalent
26.
High Response
Shock and
Cavitation Valve
To be suitably selected
Rexroth, Parker or
equivalent
27. Hydraulic Hose
Various sizes, to be suitably
selected
Parker or
equivalent
28. Fitting
Weld nipple type of Parker soft
seal
Parker or
equivalent



SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
40


4.5 Electrical and Electronic Sub-Systems
Electrical and electronic sub-system consists of control desk master
controller (PLC based), PLC,HMI and SCADA software, MCC Panel, winch
power panel, encoders & sensors, operator display with HMI software,
operator control desk, power slip ring and FORJ assembly, cradle camera and
accessories. PLC based master controller controls and monitors the winch
operation. Winch power panel supplies power to all platform equipments. To
measure, display and record of various parameters of the winch and mooring
system encoders and sensors are used. Power slip ring transfers the power
between stationery and rotary parts and FORJ will transfer the data from the
rotary to stationary parts and vice versa. Data storage facility should also be
provided to store the various data for a period of at least one week. The main
subsystem is described in succeeding paragraph.

4.5.1 Operator Cabin and Control Panel:
A control console will be provided with a joystick for various winch
control and a display for viewing operating parameters. It should be
ergonomically designed and should have push button/touch pad, selector
switches and indicating lamp for control and monitor of the system. It should
also have indicators to indicate the winding and unwinding position of main
winch, close haul winch, nose line winch and status of electrical and hydraulic
subsystems. The operator cabin consists of following:

(a) Main controller:
It would provide controls for operating the motors and indicate system
status.
(i) Should consists of a Human Machine Interface (MIL grade flat
Panel TFT display and keyboard and touchpad )
(ii) Should operate on 230 V AC, 50 Hz
(iii) A back-up power supply should be provided to operate the
system for at least 30 min.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
41

(iv) CPU having state of art processor and motherboard with PC
slots (4 minimum) for analog/digital input/output.
(v) Should be accompanied by a software for co figurate the system
and to monitor system status.
(vi) System should have at least 500 GB hard disk.
(vii) Should have soft switches as listed below
a. HOME
b. ERROR LOG
c. PARAMETER SET
d. ALARM
(viii) Should also have lighted push buttons for controlling winch
independently & LED indicator for indicating status of winch.
(ix) Graphics Terminal: The graphics terminal is configured to
display the status of system. Various soft switches are activated
via feather touch switches to the left of the display. The various
soft switches are listed below
(a) HOME: Returns the display to the HOME screen.
(b) ERROR LOG: Display the error log, which maintains the
record of occurrences of all the errors in the system for a
period of 30 days. The information displayed on the screen
should be recorded for offline viewing. The field tabulated in
the error log are:
Serial number
Error Description
Time of occurrence
Time when the error was accepted (Alarm Reset Time)
Time when error was corrected
(c) PARAMETER SET: Display screen where control
parameters can be set:
Serial number
Parameter


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
42

Setting of the parameter
New value for setting
Restore original value
Restore to default value
(d) ALARM ACCEPT: Key to acknowledge all identified
alarms and mute speaker.

The reference detail of PLC is as follows:
The entire Winch and Mooring system is realized around a
Programmable Logic Controller The PLC is divided into the following
MODULES:

i. Power Supply Module: CPS
ii. Central Processing Unit module: CPU
iii. 64 Channel Digital I/P Module: DI1
iv. 64 Channel Digital O/P Module: DO1
v. 8 Channel Analog I/P module: AI1
vi. 8 Channel Analog O/P module: AO1
vii. 2 Channel Counter module:CMT1
viii. 4 Channel Counter module: CMT2
ix. Spare Channel
x. Spare channel
xi. Spare channel

The Ladder Logic Software should be used for the PLC is PL7-
pro or higher version or equivalent software. The Human Machine Interface
(HMI) Software for the operating system (OS1) should be Citect or equivalent
having minimum 500 tags.
The PLC controls the following Digital Input/ Output elements of Winch
and Mooring system:



SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
43

I) Motor-1 (ON/OFF)
II) Motor-2 (ON/OFF)
III) Hydraulic Motor 1 ON F/B
IV) Hydraulic Motor 2 ON F/B
V) Nose Probe lock (Engage/ Disengage)
VI) Nose probe (Engage/ Disengage)
VII) Pneumatics (ON/OFF)
VIII) Pneumatic Pressure Sensor 1
IX) Pneumatic Pressure Sensor 2
X) Trestle (Inflate/ Deflate)
XI) Hooter (Acknowledge)
XII) Footswitch (Trigger)
XIII) Capstan Manual( Engage/ Disengage)
XIV) Strowdrum manual (Engage/Disengage)
XV) Stowing Drum( Standby/ Primary / Emergency mode)
XVI) Capstan (Standby/ Primary / Emergency mode)
XVII) Left Haul Winch (Standby/ Primary / Emergency mode)
XVIII) Right Haul Winch (Standby/ Primary / Emergency mode)
XIX) Cradle Actuator (Standby/ Primary / Emergency mode)
XX) Tower Elevate (Standby/ Primary / Emergency mode)
XXI) Nose Line Winch (Standby/ Primary / Emergency mode)
XXII) Pedestal (Standby/ Primary / Emergency mode)
XXIII) Cradle Free Slide (ON/OFF)
XXIV) Spooler Manual (Engaged/ Disengaged)
XXV) Chillier Unit (OFF)
XXVI) Oil level Critical
XXVII) Pressure line filter Clogged
XXVIII) Return line filter Clogged
XXIX) Suction line offline
XXX) Suction line 1
XXXI) Suction line 2


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
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XXXII) Main Supply is OFF (Display)
XXXIII) 7
th
turn proxy tripped
XXXIV) Spooler manual (Engaged/ Disengaged)
XXXV) Hydraulic Power Pack Motor 1 ON
XXXVI) Hydraulic Power Pack Motor 2 ON
XXXVII) Pneumatic ON
XXXVIII) HPP (Loading/Unloading)
XXXIX) Cradle Actuator (free Slide)
XL) Capstan Motor ( Displacement Pilot signal- Solenoid 1)
XLI) Pedestal Clutch Operation
XLII) Pneumatic Solenoid 1
XLIII) Pneumatic Solenoid 2
XLIV) Stowing drum Lamp ( Primary / Emergency mode)
XLV) Capstan Drum Lamp ( Primary / Emergency mode)
XLVI) Left Haul Winch Lamp (Primary / Emergency mode)
XLVII) Right Haul Winch Lamp (Primary / Emergency mode)
XLVIII) Cradle Actuator Lamp (Primary / Emergency mode)
XLIX) Tower Elevated Lamp (Primary / Emergency mode)
L) Pedestal Lamp (Primary / Emergency mode)
LI) Nose Probe Docked Lamp
LII) HPP Motor-1 Lamp ON
LIII) HPP Motor-2 Lamp ON
LIV) Nose Probe Lock Engaged
LV) Pneumatics lamp ON
LVI) Trestle(Airbag) Inflate Lamp

The PLC controls in Analog mode the following elements of WM
system:

i. Pneumatic Pressure Sensor
ii. Temperature Sensor


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
45

iii. Joystick Travel (X/Y Axis)
iv. Tensometer-1 feedback (HTS)
v. Tensometer-2 feedback (LTS)
vi. Stowing drum Proportional Valve
vii. Capstan Proportional Valve
viii. Close Haul Winch Right Proportional Valve
ix. Close Haul Winch Left Proportional Valve
x. Nose Line Winch Proportional Valve

The two counter modules of 2 Channel and 4 Channel controls the
Capstan and Stow drum.

The Block diagrams of the various channel is shown in the
succeeding pages. These block diagrams are for reference only. The
actual configuration and the system will be finalized during design and
review of the system.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
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WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
46


i. Block Diagram of PLC based WM System:




































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



Central
Power
Supply

Operating System
(HMI Software)
Central
Processing
unit with
Ethernet
Port

Digital
Input
Port
Digital
Output
Port

Analog
Input
Port

Analog
Output
Port

Counter
Module
2 CH
Counter
Module
4 CH

Joystick
and
Keyboard
Inputs
Analog O/p Signals
Ack. and
Feedback
Signal
Digital Signals
Ack. and Feedback Signal

Capstan Stow drum
Feedback Sig

Feedback
Sig



SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
47


Joystick and Toggle Switch Input for the
Operation of Actuators
Cradle

Pedestal

Close Haul
winch (R)
Close Haul
winch (L)

Nose Line
Winch

Tower
Elevator

Capstan Stowdrum
Hydraulic Actuators of Winching Assembly

Ack. and Feedback
Signal
Display on Screen
Via (HMI Software)
230 VAC
Turn Count
Signal of
Capstan
Turn Count
Signal of
Stowdrum

Ack. and Feedback Signal

Digital Signal
Central
Power
Supply

Central
Processing
unit with
Ethernet Port

Analog
Input
Port
Analog
Output
Port
Digital
Input
Port

Digital
Output
Port


Counter
Module
2 CH
04
Redundant
Channels
for further
Expansion
Counter
Module
4 CH

0-10 V 0-10 V 0-10 V 0-10 V
0-10 V
0-10 V
0-10 V
0-10 V
0-10 V (x-axis)
0-10 V (y-axis)
24 V
Encoder Encoder Encoder Encod
er
Encod
er
Limit
Switch
Limit
Switch
Praportional Valve to control oil
flow


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
48

iii) Digital Input/ Output elements of WM system












































iv) Analog Input/ Output elements of WM system
Pedestal (S/ P/ E mode)
Tower Elevate (S/ P / E
mode)
Nose Probe lock (Eng/ Diseng)
Nose Line Winch (S/ P / E mode)
Capstan Manual( Eng/ Diseng)
Capstan (S/ P/ E)
Stowdrum manual (Eng/Diseng)
Stowing Drum( S/ P/ E mode)
Left Haul Winch (S/ P/ E mode)
Right Haul Winch (S/ P/ E mode)
Spooler Manual (Eng/ Diseng)
Suction line offline/1/2
Pressure/ Return line filter Clogged
Capstn Motor ( Disp. Pilot sig-
Solen 1)
Spooler manual (Eng/ Disen)
7
th
turn proxy tripped
Cradle Actuator (S/ P/ E mode)
Cradle Free Slide (ON/OFF)
Cradle Actuator (free Slide)

Pneumatics (ON/OFF)
Pneumatic Pressure Sensor
Pneumatic Solenoid 1/2
Trestle (Inflate/ Deflate)
Footswitch (Trigger)
Chiller Unit (OFF)
Pedestal Clutch Operation
Hooter (Acknowledge)
Main Supply is OFF (Display)
Lamp (P/ E mode):
Trestale Inflate /Pneumatics /HPP
Motor 1-2 / Nose Probe Docked
/Stowing drum /Capstan Drum /Left
Haul Winch /Right Haul Winch
/Cradle Actuator /Pedestal/ Tower
Elevated
Motor-1/2 (ON/OFF);
HYD Motor 1/2 (ON F/B)
Oil level Critical
HYD Power Pack Motor 1/2 ON
HPP (Loading/Unloading)
Digital
Input
Port
Digital
Output
Port

Central Processing unit with
Ethernet Port (Slot 1)
Feedback/Ac
knowledgeme
nt


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
49




























v) Counter Module elements of WM system


















(b) Motor starter Panel:
Stowing drum Proportional Valve
Capstan Proportional Valve
Close Haul Winch Rht Prop. Valve
Close Haul Winch Lft Prop. Valve
Nose Line Winch Prop. Valve
Joystick Travel (X/Y Axis)
Tensometer-1 feedback (HTS);
Tensometer-2 feedback (LTS)
Temperature Sensor
Pneumatic Pressure Sensor
Central Processing unit with
Ethernet Port (Slot 1)
Analog
Input
Port
Analog
Output
Port

Feedback/
Acknowledgement
Central Processing unit with Ethernet Port
Feedback/
Acknowledgement
Counter
Module
2 CH
Counter
Module
4 CH

Capstan Stow drum


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
50

Main purpose of this panel is to control the operation of the
motors and provide a means of protecting the motors under such fault
conditions as main motor winding overheat, single phasing, sustained
overloads and stalling. Above information related to motor condition
should be displayed in the main control panel.

(c) Encoders and load cell:
These are sensors used for sensing the various signals such as
position of the paid out length of cable or tether so that speed of paying
out of the length paid out can be calculated and number of other
parameters also.
Load cell are used to measure the tether tension before and
after the capstan.The Specification of the load cells are:
Data sheet for High tension load cell
1. Application Measurement of load in High tension side of
Capstan
2. Load Range 0 to 50000 N
3. Safe load limit 200% of full Scale Reading
4. Protection class IP 65
Data sheet for Low tension load cell
1. Application Measurement of load in High tension side of
Capstan
2. Load Range 0 to 15000 N
3. Safe load limit 200% of full Scale Reading
4. Protection class IP 65

(d) Slip rings and FORJ:
The slip ring and FORJ hybrid assembly to be fitted at the stow drum
however only slip ring with 50mm central hole is to be fitted at the
pedestal.
Technical Specifications of HYBRID FORJ Assembly at Stow Drum


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
51

i. Optical Details
Numbers of optical channel : 06, Single Mode (SM)
Wave length window () : 1310 1550 nm
Insertion loss : 3.0 dB
Connector/Adaptor : ST preferably
ii. Electrical Slip rings
Sl. No. Application Nos. of rings Current Rating Voltage rating Material
1. Power 03
02
15A
40A
1000V
1000V
Silver plated copper
Silver plated copper
2. Lightning
current drainage
01 Slip ring should be capable of passing 100KA current
for time duration of 500sec.
3. Adaptor 01 A electrical Mil grade adaptor to be provided to meet
above requirement.

iii. Mechanical Details:
Material : Aircraft Al (ASTM B 221) preferably
Rotation of power or data signal : 360 continuous
Weight : < 12 kg
Dimensions : Length 400 10mm, 200 5 mm
iv. Environmental Details:
Environmental protection : IP 65
Temperature range Operational : -10 to + 55 c
Storage : -20 to + 70 c
Vibration : Mil-std-167-1 ship vibration
v. Quantity:
Quantity required : 02 Nos.(keeping 01 as spare)
Make: M/s Princetel Inc., NJ, USA
Figure 25: Drawing of Hybrid slip ring and


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
52

Specification of the slip ring at the Pedestal
The above specification is for reference only.

(e) 3 Automatic voltage controller (8 kVA):
3 Automatic voltage controller is required to maintain 415 V
(phase to Phase) at airborne end when power supply of 8 kVA is feed
through 1500 m length of tether. A suitable automatic voltage controller
is required to made to suit this requirement.





1. Make Schleifring and apparatebau GmbH, Germany or
equivalent
2. Power Rating 250 kVA
3. Channel 11, One channel is dedicated for grounding the
lightening current of 100 kA for time duration of
500sec, one channel is used for taking the data out
and giving command when remote operation is required
4. Current rating 600 A (min)
5. Voltage rating 415 15 v
6. Central hole
diameter
50 mm
7. Protection class IP 65
8. Temperature range
Operational
Storage

-10 to + 55 c
-20 to + 70 c
9. Vibration Mil-std-167-1 ship vibration
10. Adaptor A electrical Mil grade adaptor to be provided to meet
above requirement.
11. Frequency 50 Hz


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
53

(f) Portable Rugged Online data steaming and data storage &
analysis device:
A portable rugged online data streaming device and a portable
data storage and analysis device should be provided with the system
for analysis and data back up at the trial site. Each of one number is
required.
The rugged portable online data streaming device should have
MIL grade components and of reputed make. The some of the
minimum features are:
250 GB Hard disc(or higher), 2 GB DDR2 RAM (or higher), 13.3
LCD, Intel core 2 duo with corresponding motherboard, standard port
and interfaces like RJ 11, RJ 45, Serial, 4 USB, port replicator
interface, VGA out, Audio in out, Intel 3945 a/b/g, 10/100/1000 Gigabit
NIC, Blue tooth, DVD writer, standard keyboard with touch pad, pre
installed Windows 7 professional, battery life not less than 6 hours etc.
The portable data storage and analysis device should be of
reputed make. The some of the minimum features are:
500 GB Hard disc(or higher), 3 GB DDR3 RAM (or higher), 12.1
TFT, Intel core i7 processor with corresponding motherboard, standard
port and interfaces like RJ 11, RJ 45, Serial, 4 USB, port replicator
interface, VGA out, Audio in out, Intel 3945 a/b/g, 10/100/1000 Gigabit
NIC, Blue tooth, DVD writer, standard keyboard with touch pad, pre
installed Windows 7 professional, Web camera, battery life not less
than 4 hours etc.

(g) List of electronic control system deliverables:
(i) Master controller
(ii) System Software with their licenses
(iii) Console with HMI, CPU
(iv) Feedback Sensors


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
54

(v) Operator desk with SBC and operator dialog terminal and
push buttons and levers
(vi) Networking cable and associated hardware
(vii) MCC Panel
(viii) Slip rings (one of 8kVA rating other 250 kVA rating)
(ix) Hybrid FORJ (2 no. one for the stow drum other for
spare)
(x) 3 Automatic voltage controller (8 kVA)
(xi) Portable rugged data streaming device
(xii) Portable data storage and analysis device
(xiii) Back up supply
(xiv) Communication system for maintenance crew and
operator
(xv) Engineering services
(xvi) Commissioning services


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
55

4.6 Miscellaneous subsystem
4.6.1 Pedestal Drive and Slewing Bearing
The entire mooring station is mounted on the pedestal using a slewing
bearing. The slewing bearing allows the station to be rotated continuously
about the vertical axis. The powered drive unit coupled to the slewing bearing
allows the complete winch and mooring system to be oriented as required
using a hydraulic motor. The operational controls for this are available at the
operator control desk. It can be disengaged from the operator control desk to
allow wind waning.
The specification of this subsystem is given below:
Specification Sheet - Aerostat Pedestal Drive
1. Application: Flange mounted Pedestal Drive with
integral clutch for Mobile application
2. Dimensional Data:
Mounting PCD
Body diameter
Total height

< 500 mm
< 350 mm
< 300 mm (from mounting flange to
motor end face)
3 Input Interface: Hydraulic Motor
4. Output Torque: Dynamic: 1500 Nm
5. Output Speed: 5 rpm
6. Output Pinion Details: Module = 5
Number of teeth = 73
7. Output Interface:

Length of pinion shaft such that length
from mounting face to pinion center =
48 mm
8. Clutch Details: Hydraulically engaged spring released
clutch. Preferably non friction based
positive engagement
9.

Sealing: Fully sealed against ingress of dust /
water


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
56

10. Weight: Reduced component weight preferred
11. Life: 10 years (assuming operated (@ 2hrs
per day)
> 7200 hours (1.8 X 10
5
(No. of cycles
@ 25 half cycles

Note : This specification sheet are for reference only.

Specification Sheet - Aerostat Slewing Bearing
1.
Application: Slewing Bearing for Mobile
application (Wind-vaning Station)
2. Bearing Type: Slewing bearing With Internal Gear
3. Make: Rothe Erde, Germany or Equivalent
4.
Dimensional Data: Maximum External
Diameter:
Maximum Height :

2000 mm
300 mm
5.
Accuracy
Axial Run out on the mounting faces:
Radial run out on locating spigots:
Run out on gear PCD:

< 0.2mm
< 0.2 mm
< 0.12 mm
6. Starting Torque: < 1000 Nm
7.
Bearing Loads:
During Transportation:
Operational load:

60 ton
30 ton
8.
Gear:
Maximum Operational Torque :
Operating Speed :

6 kNm
1 rpm
9. Sealing:
Fully sealed against ingress of dust /
water
10. Weight:
Reduced component weight
preferred


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
57

11.
Bearing Life: 10 years (assuming operated(@
2hrs per day)
> 7200 hours (1.8 X 10
5
(No. of
cycles @ 25 half cycles per hr))
Suitable azimuth rotating mechanism or equivalent may be used which meets
system requirement.
Note : This specification sheet are for reference only.

4.6.2 Air Conditioning System
Air conditioning system is used to maintain the temperature and
humidity of the operator cabin as well as the winch enclosure. The air
conditioner should be suitably chosen so that the temperature inside the
operator cabin and the winch enclosure is comfortable even at the extreme
operating condition. Air conditioner should have MIL grade type.

4.6.3 Pneumatic System and Air bags
The Pneumatic System is solely for the purpose of inflating and
maintaining the pressure in the Air Bags during operating conditions and to
deflate Air Bags during transportation condition. Pneumatic system consists
of compressor/ air cylinder, vacuum pump, air bags, pressure control valve
and other accessories. Compressor/air cylinder and vacuum pump is used to
inflate and deflate the air bags respectively. To control the pressure of air
during the inflation or deflation of air bags, pressure control valves are used
along with other accessories to ensure the proper distribution of air.
The function of the airbags is to support balloon in docked condition. It
is suitably located on the winch and mooring system. It has two frames which
are welded to the main structural frame of the station. Each frame carries an
inflatable Air bag, which provides cushioned support to Aerostat to keep it in
horizontal position.
4.6.4 Lightning Protection: The tether is having lightning braids to cater 100
k Amps lightning. Adequate path should be available to earth the lightening.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
58

5.0 Scope of Work
It includes development, fabrication, supply, integration of structural,
hydraulic & control system, installation, commissioning of the system at
ADRDE and conduct test trials as per ATP. This system requires a preliminary
& critical design analysis, Material Selection, preparation of drawings,
Fabrication & testing techniques. Finite Element Analysis of various structural
members would be necessary to arrive at a rational mechanical design of the
system. The scope of work mainly includes following:
a) Design of whole system based on specification including FEM
analysis of the system.
b) Preparation of Configuration Document, Preliminary Design Report
(PDR), Critical Design Report (CDR) etc.
c) Review of the design by experts to be nominated by ADRDE.
d) Preparation of manufacturing drawings of all the systems and
components including assembly drawing in AUTOCAD and 3D
modelling duly approved by ADRDE. (The firm should have in
house CAD facilities and they are at least 5 years experience in
fabrication and FEM analysis of structures and components).
e) Review of acceptance Test Procedure (ATP) based on draft ATP
provided by ADRDE and then preparation of final ATP.
f) Preparation of QAP and WPS (Welding Procedure Specification)
Document.
g) Fabrication of the complete system.
h) Testing of sub-assemblies of the system as per ATP at firms
premises.
i) Integration, installation and commissioning of whole system at
ADRDE, Agra or place provided by ADRDE, Agra.
j) Fabrication of test jigs and fixtures required in manufacturing and
testing.
k) Acceptance Testing as per final ATP.
l) Preparation of Test Report (including stage inspection report).


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
59

6.0 Inspections and Acceptance Procedure:
During complete execution of the job, inspection will be carried out by
the Director ADRDE, Agra or his authorized representative. The inspection
will be carried out in stages for raw materials, machined components,
assembled components and bought out components. The contractor shall get
the drawings approved for every component including structure, hydraulic
circuit, various sensors and bought out components. All the material to be
procured by the contractor shall be inspected by the inspecting authority i.e.
Director ADRDE or his authorized representative. Stage inspection shall be
carried out for subassemblies during fabrication. Contractor shall keep
informed the inspecting authority on the progress of work and shall notify the
inspecting authority well in advance. Inspection report format for each
component has to be filled in separately for critical dimensions on each
component using calibrated instruments only. All inspection, measuring and
test equipment should have valid calibration as per ISO 9001 requirements.
The system should be inspected and accepted as per final ATP which will be
prepared after the review however the draft ATP is given in the Annexure I .

7.0 Painting:
i) Cleaning: The surface to be painted shall be prepared to ensure
complete removal of grease, rust scale corrosion, slag etc.
Mechanical cleaning involving Scraping, wire brushing, rubbing
with abrasion paper may be used.
ii) Primer Coat: Primer coat shall consist of red oxide zinc chrome
confirming to IS: 2074. Two coats of this shall be applied as per
the procedure laid down in IS 1477 Part II. (painting process to
be approved by ADRDE)
iii) Finish Coat: Two coat of OG colour paint.
iv) Adequate internal protection should be provided to the structure
components used as hollow sections.




SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
60

8.0 Integration, Installation and commissioning:
The integration, installation of the whole winch and mooring system will
be carried out by the contractor initially at firms premises and then at ADRDE,
Agra or the place provided by ADRDE Agra. After the installation the system
will be commissioned by the firm at ADRDE, Agra or the place provided by
ADRDE Agra.

9.0 Materials for Fabrication/Integration/installation:
i) All the materials, tools, accessories, Welding set, crane required
for integration and testing is to be arranged by the contractor at
the work site (at firm premises or at ADRDE or place provided
by ADRDE) at his own cost.
ii) All the materials required for fabrication will be procured by the
contractor along with their relevant test certificates. Material
procured by the contractor for machining and fabrication work
should confirm to relevant IS specification. Material, which is not
confirming to the specification, will be rejected and will be
replaced by the contractor at their (contractor) cost. The
contractor shall furnish test certificates for all the material
purchased by him confirming to relevant standards before
commencement of work. Material shall be tested for its chemical
composition, mechanical properties, ultrasonic test etc to detect
any flaws before fabrication. The materials shall be stamped by
the inspection agency before fabrication.
iii) Firm should submit the QAP document, which will describe how
raw material will fabricate into component.




SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
61

10.0 Quality control:
As quality is integral part of the service process, so to enable the
effective control of each service process the contractor should use calibrated
instruments during manufacture of all the components. If such calibrated
instruments are not available, the contractor should make necessary
arrangements and provide calibrated instruments to the inspector as and
when inspection is carried out. The contractor should strictly adhere to the
tolerances specified in the approved drawings. Contractor should submit
quality test plan along with technical bid.

10.1 Quality control for welding:
i) Welding sequence shall be such that the distortions and
residual stresses are minimized. All welds shall be
deposited in proper sequence so as to balance the
applied heat as far as possible.
ii) All welding shall be carried out by qualified and approved
welders. Quality of welds carried out by the welders shall
be tested in accordance with IS:7318 before the welder is
permitted to do the welding.
iii) In case of fillet welds, test coupon shall be made and
subjected to dye penetration test. The welding
parameters of the accepted weld coupon be established
and ensured in case of fillet welds.
iv) Weld metal shall be solid except for the fine scattered
porosity and small inclusions of oxides or slag may be
overlooked.
v) There shall be complete fusion and penetration between
the weldment and the parent material during the
successive runs.
vi) Firm should submit the WPS (Welding Procedure
Specification) document.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
62


11.0 Perfection of Work:
i) All components and accessories shall be suitable for open field
operating conditions including dust, sand, rain, salinity etc. For this,
all components shall have anticorrosion treatment & should be dust
proof. All mating components shall have proper lubricating
arrangements.
ii) The workmanship shall be of the highest in order. All components
should be free from burrs, sharp edges and finished smooth.
iii) All components and accessories having same part numbers shall
be directly interchangeable with respect to installation and
performance. The list of all spares should be supplied
iv) The components that are used in fabrication of this system should
be of reputed firm/company. The overall workmanship shall be of
best quality to the satisfaction of inspection agency. All
components/accessories should be of best trade quality and as far
as possible should conform to IS specification.
v) In the hydraulic drives, all the pipes should be bent neatly to the
appropriate angle and be properly clamped and secured. Sharp
bends should be avoided. No leakage what so ever in pipe joints
and connections are allowed.
vi) The electric motor along with the hydraulic pump, hydraulic motor
and all other accessories shall be properly placed and mounted.
vii) All the control valves shall be properly mounted on a panel in such
a way that all the hydraulic components/fittings should be easily
approachable and if needed be easily removable and re-fittable
during repair/maintenance.
viii) Hydraulic power pack shall be compact in design.
ix) Fabricated components should be free from burs and sharp edges.
x) The fabrication and welding of system shall be of highest quality.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
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Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
63

xi) All the components shall be manufactured as per the tolerances
mentioned on the approved drawings. Unless otherwise specified,
the tolerance for fabrication shall be as per IS: 2102 1993.
xii) All supplied electronics subsystems should be of Industrial/MIL
grade. All electrical subsystems should meet environmental
condition as per JSS 55555.
xiii) All sub-vendor (if any) should be approved by DIRECTOR, ADRDE.

12.0 Safety requirements:
Safety has to be of prime importance to avoid any accident and injuries
to the personnel working on the system. The following safety measures
should be kept in mind during integration:
i) All high pressure components/lines shall be properly covered to
avoid damage due to falling of some objects or tools and prevent
people to step on such components/lines during working.
ii) Proper colour code shall be followed for marking of
components/lines as per standard practice.
iii) All hydraulic pipe lines shall be properly clamped as per standard
practice to avoid loose connection and thereby leakage due to
vibration during running of pump and motor.
iv) Indian standard IS: 10481 Guide lines for application and
installation of oil hydraulic system shall be followed for installation of
hydraulic system.
v) Items that will be used for the fabrication of the above system
should be of flame proof quality.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
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64


13.0 Tools for maintenance:
i) Tools like Allen Key set inch and mm series, double ended spanner
set, screw driver pipe wrench, adjustable wrench and any tools
required for maintenance of hydraulic system or any component to
be supplied by the contractor with the system.
ii) Special maintenance tool required for specific hydraulic
components as well as other components shall be supplied by the
contractor.

14.0 Jigs and Fixtures
All critical welding shall be carried out using welding fixtures. The
welding fixtures shall be designed and fabricated by the firm. These shall be
approved from the inspector. All the welding fixtures shall be robust for
repetitive use. The welding fixtures shall not develop undesirable clamping
stresses in the components being fabricated. The welding fixtures shall
facilitate easy and proper welding of components from all sides.

15.0 Deliverables:

a) A complete set of detailed manufacturing drawings (in 3D and 2D) of
every supplied component along with assembly drawing in both hard
as well as soft form.
b) Complete Design Report i.e. Configuration document, Preliminary
Design Report (PDR), Critical Design Report (CDR) (including FEM
Analysis report) in both hard as well as soft (in solid model) form.
Document should be given in doc format.
c) QAP and WPS Document in both hard as well as soft (in solid model)
form. Document should be given in doc format.
d) One set of fabricated Winch and Mooring System along with Trailer
and spares. List of spares is attached as Annexure -II.
e) Schedule of spare parts with proper part nos. and source of supply and
portable rate of consumption.


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
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f) List of all brought out items with their test certificates.
g) System description, Operational, maintenance and repair/trouble
shooting manuals.
h) Inspection and test reports of all components as well as the assembly.
i) Compliance report of the Acceptance test of the winch and mooring
system.
j) Part list, part specification with literatures of all components. The
catalogue and data sheet of all brought out item.
k) Drawings of hydraulic circuit and plumbing and bill of materials.
l) The winch and mooring should be suitable for inflation and deflation of
the Aerostat when moored at the mooring structure. Fixtures for this, if
any, are to be provided by the supplier.
m) Recommended spares for two years maintenance shall be supplied.
n) Spare kit as recommended by manufacturer for all hydraulic
components/ control valves and accessories used in the system shall
be supplied.
o) Hydraulic hoses, tubes, end fittings connectors etc. required for two
years of maintenance of the system are to be supplied.
p) Access ladders
q) Electronics deliverable as per point no. 4.5.1.(g)
r) Warranty certificate of the complete winch and mooring system.

16.0 Time Schedule:
The complete system is expected within 18 months from placement of
SO. Total execution time shall be indicated with detailed activities like
preparation of manufacturing drawings, procurement of materials, fabrication
integration testing delivery etc shall be indicated in pert chart form at the time
of tendering. The same shall be reviewed and up dated fortnightly till the
delivery of the whole system. Firm should submit total plan and PERT chart
along with technical bid.



SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
66

17.0 Guarantee/Warranty:
The system shall be covered by a warranty for a period of two (02)
years against malfunctioning, material and manufacturing defects.

18.0 Product Support:
The contractor shall quote separately for comprehensive Annual
Maintenance Contract (AMC) for a period of three (03) years after the
completion of guarantee/warranty period, which shall include regular
maintenance and fault repair including spares and consumable to be
undertaken beyond the free warranty/guarantee period as well.

19.0 Presentation:
The firm should give presentation before a committee, which include
understanding of the complete system and how they complete the total task in
given time frame with the PERT chart .

20.0 Compliance sheet:
The contractor has to submit the completed compliance sheet
(enclosed as Annexure III) and questionnaire (enclosed as Annexure IV) to
ADRDE during submitting the tender Form.
















SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
67

1.0 SCOPE

This Acceptance test plan covers the test, inspection and acceptance
procedure of winch & mooring system for Medium size aerostat.

2.0 GENERAL
2.1 All the raw material should conform to relevant specifications as
mentioned in the drawings.
2.2 Manufacturer shall submit test reports of all raw material, only
from govt. recognised labs. Along with a certificate that all
material conform to relevant specification.
2.3 Rep ADRDE at his discretion, can draw samples from the
material and carryout test at ADRDE or at the lab considered
appropriate.
2.4 Vendor will undertake 100% inspection of all components/parts
and Inspection reports will be submitted to ADRDE.
2.5 Variation if any, observed in critical dimension/parameters, the
part/ component would be rejected.
2.6 Manufacture has to follow the process as, described in the
drawing only. Variation from specified process should have prior
approval of designer/ADRDE. Product will be rejected if process
has not been followed as per specification/ as mentioned in the
drawings.
2.7 All the test will be carried out in the ADRDE/Vendors Premises
or any other place with the approval from ADRDE, Agra.
2.8 All the checks/Tests are to be performed in presence of
ADRDE, Agra representative and a Vendor
Representative.
2.9 Vendor will provide test certificates of the all the brought out
items.


Acceptance Test Plan (Annexure - I)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
68

3.0 TEST CLASSIFICATION
In this section we mention all the tests to be performed prior to
acceptance of the systems.

3.1 Preliminary Checks
i) Objectives:
a) To check whether the dimensions of all components are within
specified tolerances or not.
b) To check whether material of requisite strength and chemical
composition is used or not.
c) To check whether finish and workmanship of the components are of
good quality or not.

ii) Preliminary test consist of following type of tests

a) Dimensional checks:
All the machined components should be checked for their
dimensional accuracy within the tolerances specified in the drawings.
These checks should be performed using suitable measuring
instruments.

b) Material checks:
All the materials used in the fabrication of various winch
components should be test for their Chemical composition and
Mechanical properties. The tested properties should have values in
accordance with those specified in the relevant standards.

c) Welding test:
Welding test is to be done during fabrication and after
fabrication. Vender will submit all the test reports.

Acceptance Test Plan (Annexure - I)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
69

(d) Finish and workmanship test:
All the machined components should be checked for Lay,
Waviness, Surface flaws, Burrs by means of a Surface micrometer. All
plated components should be tested for the plating thickness, which
should be in accordance with thickness specified in the relevant IS.
This test is essential to ensure that the peeling of plating does not
occur.

e) Lubrication Check:
The lubrication of the moving parts of the system should be
checked by imparting motion to them under No load, Full load and
Overload conditions. The motion in each of these cases should not be
accompanied by any abnormal noise due to friction or misalignment.

f) Hydraulic checks:
All brought items are checked for their test certificates. The
fabricated components are checked for their intended use and
functionality in standard hydraulic test bench or govt. approved
laboratories in standard testing conditions.

3.2 Functional Test
The functional test can be classified into two phases

3.2.1 Phase 1 (Winch assembly)
All the tests performed on winch is to be done using suitable
Test Winch which is to be fabricated by the vendor at their premises.
The test winch should be duly approved by ADRDE, Agra. Following
are the list of tests to be conducted:



Acceptance Test Plan (Annexure - I)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
70

(a) Capstan Brake load holding test:
Capstan is tested for its braking capacity i.e. 90000 N. A load of
specified value will be applied on the tether wrapped over the Capstan.
Brake should not slip and no abnormal vibration and heating should be
observed in any component. This load is gradually applied on the
tether using a suitable actuator. At maximum load i.e. 90000 N load
should be applied for at least 5 minutes.

(b) Stow drum test and spooler test:
The objective of the test is to check the performance of the stow
drum with speed varying from 0 75 m/min at a load of 6000 N.
Minimum 4 complete layer on stow drum should be checked for proper
winding and unwinding.

(c) Nose line/close haul Winch Test
These winches are tested to winding and unwinding of the rope
for specified load and speed (i.e. 1500 kg and 30 m/min).

3.2.2 Phase 2 (Integration trials)
It consists of testing of the system after integration of each subsystem

a) Synchronization test
The objective of the test is to test the synchronization between
the capstan & stow drum assembly during operational loads.
The winch is run at full load i.e. 34000 N and at specified speed
i.e. 75 m/min for 5 cycles each in winding and unwinding mode with a
pause of 5 min. and ensures smooth functioning of subsystems. (one
cycle consist of winding & unwinding of min 350 m length of tether)
b) Starting friction torque test
The objective of the test is to verify the starting frictional torque
(1200 Nm) of the Slewing bearing when complete is mounted over the
slewing bearing.
Acceptance Test Plan (Annexure - I)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
71

c) Structural test
The objective of the test is to check the structural strength of the
integrated system by simulating operational load conditions. The load
will be applied on the winch and mooring system at the various points
using crane etc. Based on the various load cases, critical load case(s)
has (have) been identified and accordingly load has been applied to
check the structural strength.

d) Cradle & latch Test
The cradle of the system should be checked for tilting through
actuator as well as the locking/unlocking of the nose probe in the latch
assembly. The locking mechanism of the nose probe will be checked
for 15000 N.

e) Mooring Tower actuator test
The objective of this test is to check the actuation mechanism of
the Mooring tower actuator & its load holding capacity for any angle
from 0 110
0
.

f) Flying sheave Test:
Flying sheave should rotate 360 degrees freely around the
horizontal axis. It should also be able to tilt on both side (port side and
starboard side) up to the stopper and return back to nutral position
when tilting load has been removed.
It should also be tested for 9000 kg load. This load test can be
combine with the structural test.

g) Operational check and Leak test of Air Bags
The Air Bags have been inflated to its maximum allowable
pressure using pneumatic power pack and checked for any leakage by
applying soap solution.
Acceptance Test Plan (Annexure - I)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
72

h) Load test

This test is performed basically to check whether the structure can
meet the loading requirements as stated in the specifications.

i) Operational check of Air Bags
The Air Bags of the mooring system should be capable of supporting
the aerostat without any leakage in the Air Bags.

j) Static Acceptance Test
The static acceptance test is intended to check whether the structure is
capable of carrying the design loads without undue distortion and
without developing serious defects.

3.3 Environmental Test:
All components/parts/subsystem supplied by the vender should
environmentally tested as specified in the specification. A test
certificate in this regard is provided by the vendor.

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

A complete trial integrating tether and Medium size aerostat will be
flown tested up to height of 1000 m and carried out performance checks as
specified in the specification. The system should meet all operational
requirements.










Acceptance Test Plan (Annexure - I)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
73



List of Spare Parts for winch & mooring system for medium size
Aerostat:

Sl. No. Item Qty Remark
1. Close haul/nose line winch assembly 1 no.
2. Stow drum and spooler assembly 1no.
3. Capstan assembly 1 no.
4. Cradle 1 no.
5. Pedestal 1 no.
6. Flying sheave 1 no.
7. Control console 1 no.
8. Tether guide assembly 1 no.
9. High tension sensor assembly 1 no.
10. Low tension sensor assembly 1 no.
11. Air bags 1 set
12. Pneumatic system 1 set
13. Pressure line filter 1 no.
14. Return line filter 1 no.
15. Hydraulic Power pack (same used in the
winch and mooring system for medium
size aerostat) with all its accessories,
valves, proportional valves, Hydraulic
Pump, Hydraulic motors, Hydraulic
cylinder for mooring tower, Rotary
actuator, oil cooler unit etc.
1 set
16. Hydraulic fittings 1 Set
17. Hydraulic Seals 1 Set
18. Hydraulic hose 1 set
19. Tyre with tube (besides 2 tyre-tube
provided with trailer)
4 no.
20. Access ladder for access to the control
cabin(It should have proper side and
overhead protection)
1 no.
21. Access ladder for access the roof of the
winch enclosure(it should have proper
side and overhead protection)
1 no.

Note: All the items should be packed nicely in such a way that they should
fulfil all the environmental as well as transportation condition mentioned in the
specification
LIST OF SPARES (Annexure II)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
74

Sl. No. Scope of work Vendor Compliance
1
Design of whole system based on specification including FEM analysis of the system.

2
Preparation of Configuration Document, Preliminary Design Report (PDR), Critical Design
Report (CDR) etc.

3
Review of the design by experts to be nominated by ADRDE.

4
Preparation of manufacturing drawings of all the systems and components including
assembly drawing in AUTOCAD and 3D modelling duly approved by ADRDE.

5
Review of acceptance Test Procedure (ATP) based on draft ATP provided by ADRDE.

6
Preparation of QAP and WPS(Welding Procedure Specification) Document.

7
Fabrication of the complete system

8
Testing of sub-assemblies of the system as per ATP at firms premises.

9
Integration, installation and commissioning of whole system at ADRDE, Agra or place
provided by ADRDE, Agra.

10
Fabrication of test jigs and fixtures required in manufacturing and testing.

11
Acceptance Testing as per ATP.

12
Preparation of Test Report(including stage inspection report)

COMPLIANCE SHEET (ANNEXURE III)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
75



Sl. No. Specification Vendor Compliance
1 The Winch and mooring system is required to hold the medium size Aerostat.

2
Mooring structure should be made in foldable modules to enhance the ease in transportation. The dimension
of the winch and mooring system in the folded condition should not be more than 12 m (length) X 2.5 m
(width) X 3.7m (height). The folding/unfolding operation should be mechanised (preferably
hydraulically/electro-mechanical). The suitable locking arrangements should be provided during transportation
and actual operational condition.

3
The winch is required to be capstan type with level winding arrangement (spooler) for uniform winding of
tether, Single tether with hydraulic as well as electronic control.

4
Mooring system should be turn table type, hard nose with nose cradle and a latch assembly. Mooring system
must have freedom of wind - vaning.

5
A pedestal hydraulic power drive is required to orient the winch and mooring system as per the requirement
of the Aerostat.

6
The winch should be capable of hoisting and de hoisting the Aerostat at a tether tension of 34000 N at
winding speed of 75 m/min.

7 The speed of the winch and mooring system should be varied from 0 to 75 m/min.

8
The Nose line winch and close haul winches should be designed to operate at 30 m/min at a load of 15000 N.
However it should withstand a load of 30000 N.

COMPLIANCE SHEET (ANNEXURE III)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
76

Sl. No.

Specification
Vendor Compliance
9
Operating limits: The system should be capable of withstanding the following conditions in different
orientations: (a) 70 Knots (36 m/s) wind speed when the balloon is moored on the structure and faces into
the wind. (b) Side force corresponding to 20 knots (10.29 m/s) wind speed, which acts in case the bearing
fails to rotate.

10
Winch and mooring system is capable of withstanding 90000 N acting at the flying sheave. The structure,
flying sheave, Pulleys etc should be design to withstand that much of load.

11 The whole structure should able to rotate freely at a torque value 1200 Nm or less.

12
The break holding capacity of the winch system should be 90000 N. It means that when this much of load will
come on the tether, the tether should not unwind itself from the winding drum.

13
All Aerostat program e.g. launching, recovery, mooring, controlling etc can be done should be done at single
place i.e. at the operator cabin inside the winch enclosure. Provision should be made so that operator can
communicate with other crew members.

14
A provision should be made in the cradle and latch assembly for automatic release of nose probe from the
cradle.
15
Provision should be made to digital display and record the various parameters e.g. winding/unwinding speed
of the main winch, tether tension value before and after the capstan, tension value of the nose line and close
haul lines, Tether released out from the drum and tether storage length, Temperature of hydraulic oil, level of
the hydraulic oil in the reservoir etc.

COMPLIANCE SHEET (ANNEXURE III)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
77

Sl. No.

Specification
Vendor Compliance
16
Data logging facility should be provided to record the data for minimum Fifteen (15) days. A rugged storage
data device should be provided along with the system.

17
A portable data storage and analysis device and a online rugged data streaming device should also be
provided for analysis of the store data.
18
All operation should be done by joystick provided at operator cabin. However provision should also be made
to operate the system through hydraulic lever through PVG for redundancy. In case power failure the manual
operation should also be provided.

19
The operator can also operate the system form the ground through remote/operator panel, instead of sitting
in the operating cabin if the need arises. A Radio Frequency link in this regard should also be available.

20 Pneumatic Power Pack and airbag is controlled and operated from the controller cabin.

21
The winch should be automatically stop the operation when the seventh (7
th
) turn of the lowest layer of the
tether remains on the stow drum.

22
Synchronization of two close haul winches, nose line winch, capstan and stow drum will be made. This
means capstan, stow drum, two close haul winch and nose line winch should be operated simultaneously at
same speed. The maximum winding/unwinding speed in this case will be 30 m/min

23
The winch and mooring should be suitable for inflation and deflation of the Aerostat when moored at the
mooring structure.

COMPLIANCE SHEET (ANNEXURE III)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
78

Sl. No.

Specification
Vendor Compliance
24
All the items should be used for the fabrication of the winch and mooring system should be of flameproof &
explosion proof quality.

25
All fasteners e.g. nuts and bolts, studs etc used in the assembly should be of suitable strength and protection
with corrosion.

26 The system should be transportable by road in folded conditions.

27
Access ladder should be provided to access the operator cabin and the roof of the winch enclosure. Access
ladder should have proper side and overhead protection.

28
The hydraulic oil shall be selected as per following temperature range. Storage temperature 20
0
C to +70
0
C,
Operating temperature 10
0
C to +55
0
C

29 Cradle is able to tilt +125
0
and 45
0
from the horizontal

30 A slewing bearing of suitable capacity is to be provided which can withstand radial, axial and tilting moments.

31 Material to be used for fabrication of the structure is marine grade anti-corrosive steel.

32
One sets of Slip rigs integrated with FORJ are provided to supply the power to the prime mover as well as two
way transfer the data from the airborne to the ground. Such slip ring and FORJ is to be provided at the stow
drum to provide power and data to the tether. The Power slip ring with central hole is to be provided at the
pedestal to transfer the power from the main supply to the rotating winch and mooring system.

COMPLIANCE SHEET (ANNEXURE III)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
79

Sl. No.

Specification Vendor Compliance
33
The trailer should be suitably selected/designed to house the system as well as compatible with the prime
mover TATA LPS 4018.

34 Provision should be made to grounding the lightening braid of the tether.

35
The winch enclosure should be properly covered so that the winch enclosure is protected from dust, rain etc.
To reduce the heat load on the air conditioner the panels of the cover should be made of insulating material.

36
The critical components of the system should sustain the following environmental conditions:

a) Ambient temperature

Operating temperature range: 10
0
C to +55
0
C

Storage temperature range: 20
0
C to +70
0
C

b) Humidity: up to 95% at +40
o
C, non-condensing conditions.

c) Altitude up to 3350 m from AMSL
d) Rain intensity (IS: 9000 part 16, Static pressure 100 15 kpa, 4 shower used at an angle of 45
0
for 01
hour duration).

e) Salinity (IS: 8252 part 10 Clause 4.2.2)
f) Dust as encountered in desert areas (IS: 9000 part 12, Temperature 40 3
0
C, relative humidity 40% steam
of dust laden air, dust concentration less than 10 3 g for a duration one hour).
g) Fungus growth as encountered in tropical climates (not encountered in mechanical components).

COMPLIANCE SHEET (ANNEXURE III)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
80

Sl. No.

Specification
Vendor Compliance
37
The system should also be designed to cater the various load cases given in the specification at point no
3.2(xxxvii).

38
Inspection will be carried out by the Director ADRDE, Agra or his authorized representative and will be carried
out in stages for raw materials, machined components, assembled components and bought out components.

39 Painting as per point no.7.0 of the specification
40 Adequate internal protection should be provided for hollow structural component sections.
41 Integration, Installation and commissioning as per point no. 8.0 of specification
42 Materials for Fabrication/Integration/installation areas per point no.9.0 of specification
43 Quality control should be as per point no. 10.0 of specification.
44 Quality control for welding should be as per point no. 10.1 of specification.
45 Perfection of Work should be as per point no. 11.0 of specification.
46 Safety requirements should be as per point no. 12.0 of specification.
47 Warranty of the system for 2 years.
48 Delivery Period (18 months after placement of Supply order)
49 Product support (AMC)( 3 years after completion of warranty period).
COMPLIANCE SHEET (ANNEXURE III)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
81


Sl. No. Deliverable Vendor Compliance
1
A complete set of detailed manufacturing drawings (in 3D and 2D) of every supplied component along with
assembly drawing in both hard as well as soft form.

2
Complete Design Report i.e. Configuration document, Preliminary Design Report (PDR), Critical Design Report
(CDR) (including FEM Analysis report) in both hard as well as soft (in solid model) form. Document should be
given in doc format.

3
QAP and WPS Document in both hard as well as soft (in solid model) form. Document should be given in doc
format.
4
One set of fabricated Winch and Mooring System along with Trailer and spares. List of spares is attached as
Annexure -II.
5 Schedule of spare parts with proper part nos. and source of supply and portable rate of consumption.

6 List of all brought out items with their test certificates.

7 System description, Operational, maintenance and repair/trouble shooting manuals.

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

9 Compliance report of the Acceptance test of the winch and mooring system.

10 Part list, part specification with literatures of all components. The catalogue and data sheet of all brought out item.

11 Drawings of hydraulic circuit and plumbing and bill of materials.

12
The winch and mooring should be suitable for inflation and deflation of the Aerostat when moored at the mooring
structure. Fixtures for this, if any, are to be provided by the supplier.

13 Recommended spares for two years maintenance shall be supplied.

COMPLIANCE SHEET (ANNEXURE III)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
82

Sl. No.
Deliverable
Vendor Compliance
14
Spare kit as recommended by manufacturer for all hydraulic components/ control valves and accessories used in
the system shall be supplied.

15
Hydraulic hoses, tubes, end fittings connectors etc. required for two years of maintenance of the system are to be
supplied.

16 Access ladders

17 Warranty certificate of the complete winch and mooring system.

18
Electronics deliverable as per following:
(i) Master controller
(ii) System Software with their licenses
(iii) Console with HMI, CPU
(iv) Feedback Sensors
(v) Operator desk with SBC and operator dialog terminal and push buttons and levers
(vi) Networking cable and associated hardware
(vii) MCC Panel
(viii) Slip rings (one of 8kVA rating other 250 kVA rating)
(ix) Hybrid FORJ (2 no. one for the stow drum other for spare)
(x) 3 Automatic voltage controller (8 kVA)
(xi) Portable rugged data streaming device
(xii) Portable data storage and analysis device
(xiii) Back up supply
(xiv) Communication system for maintenance crew and operator
(xv) Engineering services
(xvi) Commissioning services
COMPLIANCE SHEET (ANNEXURE III)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
83



Sl. No. Task Questionnaires Vendor comment
1
Designing :
Design of whole
system based on
specification
including FEM
analysis of the
structure
(i) Whether firm has designed trailer mounted system of about 30 Ton weight in the
past. Please furnish details in brief.


(ii) Whether firm has independent design office and design team if yes, please
specify the following.

(a) How many designers are working in their design team.

(b) What are different software design tools are available with the firm. The details of
workstation/licenses of the computing/analysis software
(IDEAS/ANSYS/UNIGRAPHICS/Pro-E/SOLIDWORKS) etc. Vender should have at
least 6 licenses.

(c) Has FEM analysis has been carried out on 30 Ton or more weight class structure
in the past. Please furnish details in brief.

(d) Has the firm have the experience in designing & fabricating the winch system in
the past of about 3.5 Ton tension in the rope or more.

(e) Whether the firm has experience in designing & fabricating of Hydraulic system
for circuits of 300 bar and 300 lpm or more.

QUESTIONNAIRES (ANNEXURE IV)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
84


(iii) Whether the firm has supplied electronic/ electrical system with PLC/SBC based
in the past. Please provide details.
(iv) Whether the firm has experience in integrating multidisciplinary system in the
past.

S. No. Task Questionnaires Vendor comment
2


Fabrication: (i) Whether the firm has an overhead crane of 20 T capacity at 12 m height or more.

Fabrication of winch
and mooring system

(ii) Whether the firm has 40 x 40 m area (approx) for fabricating and assembly of the
mooring structure.

(iii) Whether the firm has TIG and MIG welding plants please specified the number.
(iv) Please specified how many welder are approved for TIG &MIG welding
procedures from competent authority.

(v) Please specify, whether firm have executed any work related to large structure in
the past.

(vi) Please specify whether the firm carried out EMI/EMC and environmental testing
on electrical/electronics equipment in the past.
(vii) Please specify that the following machines are available with the firm:

General purpose m/c (Qty)

(a) Power hacksaw
(b) Lathe (specify the capacity and quantity)

(c) Milling m/c (specify the capacity and quantity)
QUESTIONNAIRES (ANNEXURE IV)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
85

(d) JIG boring m/c (specify the capacity and quantity)

(e) Surface grinder m/c (specify the capacity and quantity)

(f) Cylindrical grinder m/c (specify the capacity and quantity)

(g) Any other m/c (specify name, capacity and quantity)
Special Machines

(a) CNC machine centre

(b) CNC lathe machine
(c) CNC milling m/c

(d) Spline cutting machine
(e) Tool room machine for making jigs and fixtures.
(viii) Please specify that following material handling equipments are available with
the firm.

(a) Fork lifter 3 Ton or more.
(b) Crane 10 Ton capacity or more.

(c) Elevated platforms.
(d) Hydraulic trolley for lifting materials.

3


Installation,
Integration,
testing, Operation
& Inspection
Facilities
Whether the firm has the following:
(i) Hard flooring on which the system can be assembled. Specify the Area.

(ii) Independent QA team & inspection lab. Knowledge of test procedures.

(iii) Measuring instruments like

QUESTIONNAIRES (ANNEXURE IV)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
86


(a) Vernior Calliper (For measuring of 1 m length)

(b) Micro meter 500 mm

(c) 3D Co-ordinate m/c

(d) Micro examination m/c for materials
(e) Capable of measuring inspection jig for 18 m structure length.

(iv) Hydraulic circuit test facility like:

(a) Leakage test

(b) High pressure test (500 bar or more)

(c) Other Hydraulic test and maintenance facility. Please specify

(v) The sufficient power available for operating 150 kW motor and alternate power
source like DG Set (250 KVA)
(vi) Load test facility & its measurement capability through strain gauge method
using software like lab view etc.

(vii) Material test lab facilities like:

(a) Spectrometer

(b) Chemical composition

(c) UTM
(d) Hardeners tester etc

(e) Radiography test

QUESTIONNAIRES (ANNEXURE IV)


SPECIFICATION
Integrated Aerostat Surveillance System-Medium Size (NAKSHATRA)
Document No: ADRDE/QMS/MEG/MSD/TS/01 Dated: September 2011
Issue: 01. Revision: 00.
WINCH AND MOORING SYSTEM FOR MEDIUM SIZE AEROSTAT
87

(f) Megnaflax testing etc.

(viii) Load test facility on mooring tower at different angle and its measurements

4

Execution of Govt.
order in the past.

(i) Firm should specify the value of a single supply order received from the
government, department of a system which they have successfully executed in the
specified time in the past. Please furnish the details.

(ii) Firm should specify the financial strength and its turnover should be more than 75
crores in the last year.


QUESTIONNAIRES (ANNEXURE IV)