TENDER FOR Electron Beam Welding machine
Page 1 of 34
Schedule of Tender
For
Electron Beam Welding machine
Central Manufacturing Technology Institute Tumkur Road, Bangalore – 560 022. INDIA
TENDER FOR Electron Beam Welding machine
Page 2 of 34
Central Manufacturing Technology Institute Tumkur Road, Bangalore 560 022
“Electron Beam Welding machine” Schedule of Tender
(To be filled in by the tenderer and returned and duly signed along with enclosure to the Schedule of Tender)
1. Name of Purchaser Central Manufacturing Technology Institute
Tumkur Road, Bangalore 560 022
2. Place of delivery Central Manufacturing Technology Institute
Tumkur Road, Bangalore 560 022
3. Delivery of Machine Required Within 8 months after placing the purchase order
4. Date of receipt of the Tender On or before 30th Nov 2015.
5. Earnest Money Deposit Rs.25,000/- as EMD is payable by Demand Draft drawn in favour of Central Manufacturing Technology Institute, payable at Bangalore.
A tender fee amount of Rs. 1145/- is to be submitted along with the tender through a demand draft in favour of Central Manufacturing Technology Institute, Bangalore
6. Validity of the tender Tender should be valid for a period of not less than 3 months from the date of offer and unless otherwise specified by the tenderer, the tender shall be treated as valid even thereafter.
7. Technical details/ Requirements for which the tender is invited.
a. As per specification enclosed (Annexure-I).
b. All details that are required in the specification must be included in the offer. Incomplete tenders are liable to be rejected.
c. Wherever numerical values are specified, tenderer shall respond with numerical values that actually correspond to the product. Any additional features/ details pertaining to the product should be enclosed separately.
d. The equipment will be finally accepted based on the compliance of the equipment with the Acceptance Criteria. The final Acceptance Criteria will be based on mutual agreement and will be finalized at the time of placing the order. Hence, the bidder has to go through the Acceptance Criteria (Annexure-II) and convey their acceptance unambiguously. They may also suggest a suitable method of verification if the proposed method is not acceptable to the bidder.
8. Price offered a. The quotation should be furnished in TWO parts in different sealed covers in the following manner.
b. The first part should contain complete technical details of the item offered along with name and address of the manufacturer, full name and address of the authorised agent, guaranteed delivery period and 2 sets of the latest catalogues. This part should not contain the price details. The EMD as indicated should also be enclosed along with the technical details. The cover should be sealed and superscribed with “ Tender Enquiry Reference and Date” and “Electron Beam Welding machine”
c. The second part should contain the Price and other commercial terms. The price should be quoted F-O-R, Bangalore. The cover should be sealed and superscribed
TENDER FOR Electron Beam Welding machine
Page 3 of 34
with “Tender Enquiry Reference and Date” and “Electron Beam Welding machine”
d. Both these covers should be put together in an outer cover sealed and superscribed with “Tender Enquiry Reference and Date” and “Electron Beam Welding machine”.
e. Break up cost for optional features and optional equipment/ accessories are to be clearly indicated.
f. If two different models to be offered, Both shall be produced in separate sealed covers.
9. Payment Terms To be indicated
10. Transit Insurance To be arranged by the supplier from supplier’s warehouse to the place of delivery and to be billed at actual.
11. Notes
a. Late offers will not be entertained or accepted.
b. All the items in the tender Specifications are to be filled in. In complete Tender Specifications may not be considered.
c. The Director of the Institute reserves the right to reject any tender / all tenders without assigning any reason.
d. In case of unsuccessful tender, the EMD will be refunded only after finalisation of contract.
e. In case of the tenderer whose offer is accepted, the EMD will be refunded only after receipt, inspection and acceptance of the equipment at CMTI, treating it as a security deposit.
f. If the supplier fails to fulfil the terms of purchase order or when the purchaser is satisfied that it is not in the interest of the purchaser to persist with the defaulting supplier, the EMD stands forfeited. Further the purchaser is at liberty to place the order on another supplier at the risk and cost of original supplier.
12. General Terms and Conditions Latest software release version to be given at the time of installation.
All software provided should be licensed to CMTI. Maintenance, Enhancement, automatic up-gradation, and
Support for 1 year for all software User manuals, all necessary training and training material
to be provided. Original Software to be supplied on CD-ROM / DVD-ROM
media. Installation commissioning testing training and proving all
the features and functions of the system supplied should be the responsibility of the vendor.
TENDER FOR Electron Beam Welding machine
Page 4 of 34
Technical Specifications of
Electron Beam Welding machine
TENDER FOR Electron Beam Welding machine
Page 5 of 34
Annexure - I Technical Specifications of Electron Beam Welding Machine
A twin gun Electron Beam Welding Machine to weld microelectronic packages or seals. Machine has to serve welding requirements of both Micro and Macro scale as per the specifications below. Sl. No. Indicated Specifications Description Remarks
A. General Description
1 Machine Configuration Electron Beam Welding machine with vertically
and Horizontally mounted Electron guns, 1cu. ft.
working chamber, X and Y axes with CNC
interpolation capabilities. As per the Figure 1.
Essential
2 Materials to be welded Stainless steel & Stainless based alloys.
Titanium and Titanium based alloys.
Copper& Copper based alloys.
Aluminium and Aluminium alloys.
Nickel based super alloys.
Niobium & Niobium based alloys.
Kovar.
Essential
B. Electron Beam Guns
1. Gun mounting Two externally mounted Electron beam guns,
1. First one mounted on the top of Welding
chamber vertically centred.
2. Second one mounted horizontally to the right
side of the chamber when viewed from the
front.(Refer Fig. 1)
Note: These two guns will be interchangeable.
In case of any exigency one of the gun can be
used as stand by. The system shall be fitted
externally to the work chamber with a dedicated
mechanical sealing system under static and
dynamic conditions. During gun movement and
gun in operation mode it shall allow to work
with highest vacuum levels (in the range of 10-5
mbar) inside welding chamber and shall be used
with CNC gun movement system.
Essential
2. Type Direct heating triode gun
Essential
TENDER FOR Electron Beam Welding machine
Page 6 of 34
Sl. No. Indicated Specifications Description
Remarks
B. 3. Gun Movement range External to chamber (For both Vertical and Horizontal guns)
1. Minimum ± 50mm travel (100mm Absolute
travel in X and Z direction) with a linear
speed of 10-2000mm/min. (Nominal). Driven
by Servo motor with CNC control.
2. Please provide positional accuracy or
resolution of Gun movement.
3. Manual override should be possible.
Essential
4. Accelerating Voltage (As Per ISO 14744)
1. 10 to 60 kV or better (steps of 1kV)
2. Ripple: 2% (peak to peak value)
3. Stability: ±1%
4. Reproducibility: ±1%
Essential
5. Beam current (As Per ISO 14744)
1. High Current Range: 0-65 mA or better (in
steps of 0.1mA)
2. Low Current Range: 0-10 mA or better (in
steps of 0.1mA)
3. Ripple: 5% (peak to peak value)
4. Stability: ±1%
5. Reproducibility: ±1%
Essential
6. Beam power 4kW- 6kW
Essential
7. Slope in and slope out Adjustable up to 1250mA/sec.
Essential
8. Beam focusing system (As Per ISO 14744)
1. Focus control by Magnetic lens.
2. Adjustable Focus current.
3. Ripple: 0.5% (peak to peak value)
4. Stability: ±0.5%
5. Reproducibility: ±0.5%
6. CNC based and manual beam focus control.
7. Focal Distance : 50 to 300 mm or better
Essential
9. Beam deflection system 1. X deflection angle : ± 3° or better
2. Y deflection angle : ± 3° or better
3. Independent setting of X and Y deflection.
4. Frequency : 0.1 to 2000 Hz or better
5. CNC based and manual beam deflection
control.
6. Oscillation of beam as per preferred function
generation by NC or controller
Essential
TENDER FOR Electron Beam Welding machine
Page 7 of 34
Sl. No. Indicated Specifications Description Remarks
B. 10. Function generator 1. Sine, square, triangle, circle, ellipse, saw-
tooth and ∞
2. Two axes sine wave outputs for deflecting the
beam in a circular pattern.
3. Two axes DC deflection for positioning of
the electron beam.
4. Square wave forms for different workspace
ratio.
5. DC deflection shall be superimposed on the
AC outputs to provide for centering the circle
during welding operation.
Essential
11. Gun vacuum pumping
system
The two Electron guns shall have two separate
vacuum pumping system with the following
specifications
NOTE: The entire vacuum
components/pumps/valves of the gun shall be
from the same source/manufacturer
(Viz. Edwards, Leybold, Agilent & Pfeiffer.)
Essential
11.1 Working Vacuum
level
10-5 mbar or better Essential
11.2 Vacuum suction
time
Less than 3 minutes Essential
11.3 Ultimate vacuum
level
1X10-6 mbar or better
Essential
11.4 Pumps 1. One Primary pump.
2. One Turbo
molecular pump
Essential
11.5 Vacuum
Measurement and
instrumentation.
Vacuum measurement by Pirani/Penning/Wide
range gauge.
(Gauge/s make and model to be mentioned in the
technical offer)
Essential
11.6 Isolation Valve Pneumatic operated cut-off valve ensuring that
vacuum is maintained in the gun when the
chamber is vented.
Essential
From Reputed Manufacturers
TENDER FOR Electron Beam Welding machine
Page 8 of 34
Sl. No. Indicated Specifications Description
Remarks
B. 12. Viewing and Beam
Alignment
1. Coloured camera to achieve 10X
magnification at shooting distance from 50-
300mm inside chamber (From top to bottom
of the chamber).
2. Video to be displayed on HMI-PC.
3. Binoculars Viewing system for manual
focussing to be provided for both EB guns.
4. Provisions for aligning the joint with beam
before welding and during welding.
5. Suitable vapour protection for optics (like
stroboscopic system).
6. A cross hair shall be superimposed over the
image to allow the position of the beam on
the joint to be precisely adjusted before
welding.
7. Seam tracking by teach in & replay system by
interpolation.
Essential
C. Welding Chamber
1. Material Non-magnetic Stainless steel
Essential
2. Width x Length x Height 305mm x 305mm x 305mm or better
Essential
3. Wall thickness The thickness of the chamber walls shall be
designed to block X-ray radiation in accordance
with international regulations. (<1μSv/h
measured 100 mm from the walls).
Essential
4. Front access door Access door shall be hinged and open towards
the left of the welding chamber when viewed
from the front of the machine.
Essential
5. View port Viewing port Ø150mm lead glass and vapour
protective removable glasses for easy
replacement shall be located centrally on the
front door.
Essential
6. Sealing System 1. Sealed door, Access ports and Pumping
system with leakage ≤ 10-6 mbar.l/s
2. Suitable leak detection ports to be provided.
3. Door ,Access ports and Pumping system shall
have suitable compatible O ring Seals.
Essential
TENDER FOR Electron Beam Welding machine
Page 9 of 34
Sl. No. Indicated Specifications Description Remarks
C. 7. Chamber vacuum
pumping
The Welding chamber shall have separate
vacuum pumping system with following
specifications.
NOTE:
The entire vacuum components/pumps/valves of
the gun shall be from the same
source/manufacturer.
(Viz. Edwards, Leybold, Agilent & Pfeiffer.)
Essential
7.1 Working Vacuum
level
10-4 mbar or better Essential
7.2 Vacuum suction
time
Less than 4 minutes Essential
7.3 Ultimate vacuum
level and duration
5X10-5 mbar or better in
less than 5 minutes
Essential
7.4 Pumps 1. One Rotary pump.
2. One Roots pump.
3. One Turbo
molecular pump with safety
interlocks .
4. One rotary backup
pump for Turbo molecular
pump.
5. Valves
Essential
7.5 Vacuum
Measurement and
instrumentation.
Vacuum measurement by Pirani/Penning/Wide
range gauge.
(Gauge/s make and model to be mentioned in the
technical offer)
Note: Suitable provision shall be made for leak
detection in vacuum pumping line with leak
detection ports.
Essential
7.6 Over-ride Manual override provision for vacuum pumps
and valves through HMI.
Essential
From Reputed Manufacturers
TENDER FOR Electron Beam Welding machine
Page 10 of 34
Sl. No. Indicated Specifications Description Remarks
D. Work Handling System
1 Configuration Refer Figure 2
1. CNC controlled X and Y Table mountable on to chamber bottom with suitable arrangement for accurate fixturing.
2. Vertical Rotary manipulator with arrangement to swap in the place of XY table. This manipulator is mounted externally, on the bottom side of the working chamber.
3. Horizontal Rotary manipulator mounted externally, on the left of working chamber when viewed from front of the machine.
With Following Specifications,
NOTE: All the components of work handling system are made of Non-magnetic material.
Essential
2. X Y Table Essential
2.1 Table size 150mm X 150mm or better
2.2 Stroke length 1. X-axis : 100mm to 200mm 2. Y-axis : 100mm to 200mm
Essential
2.3 Accuracy 1. X-axis : 50 µm or better 2. Y-axis : 50 µm or better
Essential
2.4 X. and Y. Speed 1-2000mm/min or better
Essential
2.5 Load carrying capacity
Up to 20 kg.
Essential
3. Horizontal and Vertical Rotary Manipulators
The Rotary manipulator shall have axis accuracy of 100μm. The rotary manipulator shall have centrally sliding hardened shaft with proper vacuum seal, moves inside and outside of the vacuum chamber and provision to mount the chuck inside the vacuum chamber.
Essential
3.1 Shaft Size 25mm diameter x 450mm long hardened non magnetic shaft.
Essential
3.2 Positioning for Welding
Fully hardened collet clamping. Essential
3.3 Diameter of chuck
Non magnetic high precision 70mm three jaw self aligning chucks.
Essential
3.4 Rotating Speed Rotary speed adjustable from 1rpm to 60 rpm.
Essential
3.5 Speed stability ±1% of set speed Essential
3.6 Spindle Run-out 30µm or better Essential
3.7 Drive system Servo Motor (CNC controlled) Essential
3.8 Loading Capacity 20 kg or better Essential
TENDER FOR Electron Beam Welding machine
Page 11 of 34
Sl. No. Indicated Specifications Description Remarks
E. High voltage power
supply
High voltage power supply shall be with switch
mode power supply, variable bias supply for
beam current control with an adjustable and
stabilized supply for filament heating and it shall
have following features.
1. The power supply should have ANTI-FLASH
protection.
2. Less power dissipation.
3. High voltage proof.
4. Short circuit proof (supply needs to switch
off to avoid mis-welding and loss of
expensive work piece)
5. Zero beam current during HV recovery
(Defocusing of beam to avoid miss welding
and loss of expensive work piece)
6. Oil filled tanks and top lid easily removable
for maintenance.
Essential
F.
Control System
1 Configuration The control system to be based on Industrial
PLC, industrial HMI (Human Machine
Interface), a PC and numerical control system
which shall be of latest windows based CNC
system.
The PC shall be equipped with at least
• 2 Nos. of USB ports,
• 2 Nos. of serial ports
• 2 Nos. of Ethernet ports.
Essential
2. PLC The industrial PLC working with industrial
HMI-PC supervisory system with GUI shall be
able to control following parameters of Electron
Beam Welding Machine :
1. Welding chamber vacuum Sequence.
2. Electron gun Vacuum Sequence .
3. Electron gun Isolation valve control.
4. Electric supply of gun.
5. Safety interlocks/Security system
6. CNC Interface.
7. Alarms and Security.
8. Auto Diagnostic for Maintenance.
Essential
TENDER FOR Electron Beam Welding machine
Page 12 of 34
Sl. No. Indicated Specifications Description Remarks
F.
3. PC supervisory system CNC system shall work with industrial PC,
providing the operator interface in dialog mode
with an industrial HMI (Human Machine
Interface) standard supervisor system. The
supervision program uses standard software on
latest version of Windows. It shall be responsible
for the overall management of the machine, in
particular:
1. Management of start-up modes: immediate
or deferred.
2. Management of gun settings, including
conditioning and space charge.
3. Management of the video and cross-hairs.
4. The displays of pump units, power supplies
for the gun, mechanical movements etc.,
5. Management of faults, with history.
6. Tracking the duration of use of various
components, including cathode counter
(hours), filament, pumps, etc., in order to
facilitate preventive maintenance.
7. Troubleshooting with access to each PLC
input/output variable.
Essential
4 CNC system The welding programs shall be managed by
CNC system with the following specifications :
1. Fitted with a dedicated keypad and screen.
2. The welding programs shall be created,
executed and stored by CNC system
working to meet the requirements of
standards such as ISO 14744.
3. The control system shall include hand held
pendant with electronic hand wheel and foot
switch for precise adjustment of the CNC
axes in manual mode and necessary controls
for machine operation.
4. Programming language shall meet the
standards such as ISO.
5. Supervision program shall be with standard
software on latest version of Windows
based operating system.
Essential
TENDER FOR Electron Beam Welding machine
Page 13 of 34
Sl. No. Indicated Specifications Description Remarks
F.
4 CNC system 6. Control of mechanical welding axis and the
electrical settings for the beam (accelerating
voltage in kV, beam current in mA, focus
current in mA, X and Y beam deflection
amplitude in A), linear speed in X and Z
axis(Gun axes) & XY table axes in
mm/min, rotary speed in rpm and mm/min.
7. The welding programs include all the data
required to carry out the full welding cycle.
The complete welding program shall be able
to set ramp up, dwell time, ramp down.
8. Program storage capacity in CNC memory –
minimum 10 programs and mass storage
with PC hard disk shall be a minimum of
100GB.
9. Programs can be downloaded form from the
supervisor PC. The PC's hard disk shall
serve as mass storage in the event that a
large number of programs are used.
5 Parameters display Following operating parameters shall be
displayed at the control panel:
1. Display for vacuum level in welding
chamber and gun in mbar.
2. Speed and position of manipulators and X-
Y axes Table.
3. Speed and position of gun movement.
4. Accelerating voltage.
5. Beam current.
6. Focus current.
7. Beam deflection signal (by oscilloscope).
8. Indicators for diffusion pump ready.
9. Audio-visual display (Alarm) for air/water
failure.
10. Programming with HMI (Human Machine
Interface) shall include mimic display,
alarm status, quality data recording, error
indicators, operation screen for tooling,
vacuum and weld cycle recipes.
11. Programs shall be linked to build up a fully
automatic program consisting of tacking,
penetration, cosmetic pass, deflection,
stirring, etc.
Essential
TENDER FOR Electron Beam Welding machine
Page 14 of 34
Sl. No. Indicated Specifications Description Remarks
G. Safety
1. Radiation levels to be measured in
accordance with the ISO standard-14744 or
equivalent standards.
2. The chamber shielding shall ensure
radiation levels of less than 1µSv/hour, at a
distance of 100mm from any external
surface, with a defocused beam of
maximum power.
3. Radiation shield in the equipment shall meet
the requirement of annual whole body dose
limit of 50 mSv (maximum)
4. Illumination of red warning light when the
high voltage to the gun is on.
5. Water flow, water temperature and air
pressure switches to protect the vacuum
pumping system against power supply
failure. Audible warning of failure should
be provided.
6. All rotary drives shall be fully protected by
safety guards and noise from the machine
shall be less than 70 dB
7. Safety interlocks for preventing accidental
energizing of high-voltage without required
vacuum level, opening of isolation valve
etc., shall be incorporated
8. Beam shall not be “ON” without sufficient
vacuum in gun and chamber
9. System shall have automatic trips for over
kV, over mA, filament failure and auto-
diagnostic system.
Essential
H. Online data monitoring and storage
This system shall be fitted with the equipment
and shall have the following features:
The system shall have a minimum number of
channels and allows storing of the data of the
actual welding parameters as well to plot the
curves for each parameter all along the welding
cycle.
Essential
TENDER FOR Electron Beam Welding machine
Page 15 of 34
Sl. No. Indicated Specifications Description
Remarks
H. PC shall be equipped with a software program to
record the welding data with a minimum
sampling interval of 0.05 seconds. The data
recorded for each weld shall be provided in an
Excel spreadsheet.
The following parameters are to be recorded,
1. Accelerating voltage (kV).
2. Beam current (mA).
3. Focus current (mA).
4. Linear Gun table speed (m/min).
5. X Y table welding speed (mm/min)
6. Rotary welding speed (rpm).
7. Vacuum level in gun & chamber (mbar).
I. Cooling System Suitable closed loop water cooling system
indicating the temperature, flow rate, power etc.
Essential
J. Input Electrical Supply Voltage: 415±10% Three phase and Neutral
Power: 25 kVA±10%
Frequency : 50Hz ± 1%
Earth: ≤ 2Ω
Essential
K. Test data and Documents for Electron Beam Welding machine
All test data shall be recorded along with detailed checking of beam
equipment functions and components
1 Instruction manual Essential
2 Maintenance manual Essential
3 Diagrams for all mechanical assemblies with parts lists.
Essential
4 Mechanical,Electrical and Electronic diagrams
Essential
5 Technical documentation for the main components purchased.
Essential
TENDER FOR Electron Beam Welding machine
Page 16 of 34
Sl. No. Indicated Specifications Description Remarks
K. 6 Original licence for the
software which is
purchased.
Essential
7 One soft copy of all
the manuals and diagrams
in PDF format,
as well as the
specific programs
(PLC and man-
machine interface).
Essential
8 One re-
installation CD for the PC
Essential
9 Licensed version software
CD and replaceable hard
disk installed with all the
software shall be
included.
Essential
10 Calibration certificate for
all the vacuum gauges
shall be provided
Essential
11 Spare parts list with
source of supply and
prices
Essential
12 The supplier should
provide details regarding
the safety measures
adopted in the system.
Essential
13 Manuals of bought out
items incorporated in the
system
Essential
L. Pre-Dispatch Inspection and Training
1 Pre dispatch Inspection The inspection and calibration certifications
for compliance to specified requirements for
EB gun system, control system, X-ray
radiation safety and other requirements as per
specifications shall be conducted by Third
Party Inspection in presence of CMTI
personnel.
Essential
TENDER FOR Electron Beam Welding machine
Page 17 of 34
Sl. No. Indicated Specifications Description
Remarks
L. 1 Pre dispatch Inspection Dispatch clearance shall be provided by
CMTI representatives based on satisfactory
pre dispatch inspection and testing at OEM
based on CMTI acceptance criteria (As per
Annexure-II).
EB gun system, high voltage power supply
unit, rotary manipulator, required controls
and other supply items shall be demonstrated
by integrating with work chamber as per
acceptance criteria.
Quotation for Third party inspection to be
indicated separately in the commercial offer.
2 Training Training for 2 CMTI Engineers shall be provided
at OEM's place, for at least one week during pre-
dispatch inspection covering following areas,
Operation of machine, supervisory system,
CNC programming.
Mechanical and electrical system
maintenance
CMTI shall bear to/fro air travel, boarding
and other incidentals.
Essential
M. Packaging, Delivery, Installation, Commissioning and final Acceptance testing
1 Packaging and Delivery Machine along with all the necessary systems
to be delivered to CMTI, Tumkur Road,
Bangalore-560022.
Air worthy packing of machine under
supplier’s scope.
Delivery schedule shall be 8 months Max.
from the date of placement of purchase order.
Parties shall submit their price bid on Ex-
Works basis and also show C&F charges
separately.
Essential
TENDER FOR Electron Beam Welding machine
Page 18 of 34
Sl. No. Indicated Specifications Description Remarks
M. 2 Installation Installation of the equipment shall be carried out
at CMTI, Bengaluru.
Electric supply complying to details
mentioned above will be provided at
installation site. Suppliers to provide required
kVA ratings.
Supplier should provide the UPS requirements
of the Machine with preferred make and
model.
Pneumatic supply will be provided, supplier to
indicate pressure and flow requirements
Earthing requirements to be specified.
Foundation requirements for the machine
including drawings shall be communicated to
purchaser within one month of purchase order
placement to ready machine installation site.
Overall dimension of the system, requirements
of civil work and material handling system
need to be informed in advance.
Essential
3 Final Acceptance Final acceptance will be signed only after
satisfactory erection of entire system including
EB gun system, High voltage power source,
vacuum pumping system, control system,
cabling and wiring, complete integration, testing
and commissioning at CMTI.
Essential
4 Training at CMTI,
Bengaluru
At least one week training shall be given to
CMTI personnel at CMTI, BENGALURU, after
commissioning & acceptance.
N. Safety and
Certifications
All the necessary safety regulations such as CE
compliance, low voltage directives, EMC
regulations compliance details, Alarms and
emergency switch-off in case of any
malfunctioning must be provided. The system
must be equipped with all the necessary safety
interlocks.
Essential
TENDER FOR Electron Beam Welding machine
Page 19 of 34
Sl. No. Indicated Specifications Description Remarks
O. Warranty - inclusive of
parts and labor
The complete system and its associated
hardware / software should have a standard
warranty of 24 months from the date of
installation, commissioning and acceptance
of the system at CMTI.
Maintenance/ repair /replacement of any
hardware or software component of the
system during warranty period to be done
free of cost (including expenses of Engineer
from OEM) .
Supplier modification(s) / Software upgrades
shall be intimated and same will be made
available free of cost during the warranty
period.
Spares list required and their cost for 2 years
of operation after the warranty period shall be
indicated in the offer.
Essential
Additional 12 months extended warranty may be
quoted as an option.
Optional
P. Annual Maintenance
Contract
AMC per year basis and on bulk basis (for 3
years) including parts and labor to be quoted
separately. The terms, Conditions and amount
payable for AMC should be provided by the
vendor which shall include,
1. Preventive Maintenance
2. Breakdown Maintenance
Note: AMC terms and conditions shall be agreed
upon mutually before placement of Purchase
Order
Essential
Q. List of Users Provide a list of users for the quoted model in
India with full contact details.
Essential
R. Service Support The supplier should support the system
minimum for 10 years (post warranty, with all
spares and services). Exact lifecycle of the
offered unit has to be specified.
Essential
TENDER FOR Electron Beam Welding machine
Page 20 of 34
Figure 1
Figure 2
TENDER FOR Electron Beam Welding machine
Page 21 of 34
Annexure-II Acceptance Criteria for Electron Beam Welding Machine
Sl. No. Indicated Specifications Description Inspection
type
A. General Description
1 Machine Configuration Electron Beam Welding machine with vertical and Horizontally mounted Electron guns, 1cu ft. working chamber, X and Y axes with CNC interpolation capabilities. As per the figure 1.
Physical verification
2 Materials to be welded Stainless steel & Stainless based alloys. Titanium and Titanium based alloys. Copper & Copper based alloys. Aluminium and Aluminium alloys. Nickel based super alloys. Niobium & Niobium based alloys. Kovar
Functional verification. Demonstration of penetration in stainless steel material (10mm), Aluminium & Titanium (12mm). Testing material are in the scope of supplier.
B. Electron Beam Guns
1. Gun mounting Two externally mounted Electron beam guns,
1. First one mounted on the top of Welding
chamber vertically centred.
2. Second one mounted horizontally to the
right side of the chamber when viewed from
the front.
Note: These two guns will be interchangeable.
In case of any exigency one of the gun can be
used as stand by. The system shall be fitted
externally to the work chamber with a dedicated
mechanical sealing system under static and
dynamic conditions. During gun movement and
gun in operation mode it shall allow to work
with highest vacuum levels (in the range of 10-5
mbar) inside welding chamber and shall be used
with CNC gun movement system.
Physical verification
Interchangeability to be demonstrated
TENDER FOR Electron Beam Welding machine
Page 22 of 34
Sl. No. Indicated Specifications Description Inspection type
B. 2. Type Direct heating triode gun Functional verification
3. Gun Movement range External to chamber (For both Vertical and Horizontal guns)
1. Minimum ± 50mm travel (100mm Absolute travel in X and Z direction) with a linear speed of 10-2000mm/min. (Nominal). Driven by Servo motor with CNC control.
2. Please provide positional accuracy or resolution of Gun movement.
3. Manual override should be possible
Functional verification Gun position accuracy to be demonstrated.
4. Accelerating Voltage (As Per ISO 14744)
1. 10 to 60 kV or better (steps of 1kV) 2. Ripple: 2% (peak to peak value) 3. Stability: ±1% 4. Reproducibility: ±1%
Functional verification at OEM's place by third party inspection
5. Beam current (As Per ISO 14744)
1. High Current Range: 0-65 mA or better (in steps of 0.1mA)
2. Low Current Range: 0-10 mA or better (in steps of 0.1mA)
3. Ripple: 5% (peak to peak value) 4. Stability: ±1% 5. Reproducibility: ±1%
Functional verification at OEM's place by third party inspection
6. Beam power 4kW- 6kW Functional verification at OEM's place by third party inspection
7. Slope in and slope out Adjustable upto 1250mA/sec. Functional verification at OEM's place by third party inspection
8. Beam focusing system (As Per ISO 14744)
1. Focus control by Magnetic lens. 2. Adjustable Focus current. 3. Ripple: 0.5% (peak to peak value) 4. Stability: ±0.5% 5. Reproducibility: ±0.5% 6. CNC based and manual beam focus control. 7. Focal Distance : 50 to 300 mm or better
Functional verification at OEM's place by third party inspection.
9. Beam deflection system 1. X deflection angle : ± 3° or better 2. Y deflection angle : ± 3° or better 3. Independent setting of X and Y deflection. 4. Frequency : 0.1 to 2000 Hz or better 5. CNC based and manual beam deflection
control. 6. Oscillation of beam as per preferred function
generation by NC or controller
Functional verification
TENDER FOR Electron Beam Welding machine
Page 23 of 34
Sl. No. Indicated Specifications Description Inspection type
B. 10. Function generator 1. Sine, square, triangle, circle, ellipse, saw-
tooth and ∞
2. Two axes sine wave outputs for deflecting the
beam in a circular pattern.
3. Two axes DC deflection for positioning of
the electron beam.
4. Square wave forms for different workspace
ratio.
5. DC deflection shall be superimposed on the
AC outputs to provide for centering the circle
during welding operation.
Functional verification
11. Gun vacuum pumping system
The two Electron guns shall have two separate vacuum pumping system with the following specifications. NOTE: The entire vacuum components/pumps/valves of the gun shall be from the same source/manufacturer (Viz. Edwards, Leybold, Agilent & Pfeiffer.)
Physical
verification
11.1 Working Vacuum level
10-5 mbar or better Functional verification
11.2 Vacuum suction time
Less than 3 minutes Functional verification
11.3 Ultimate vacuum level
1X10-6 mbar or better
Functional verification
11.4 Pumps 1. One Primary pump. 2. One Turbo
molecular pump
Physical verification
11.5 Vacuum Measurement and instrumentation.
Vacuum measurement by Pirani/Penning/Wide range gauge. (Gauge/s make and model to be mentioned in the technical offer)
Functional verification
11.6 Isolation Valve Pneumatic operated cut-off valve ensuring that vacuum is maintained in the gun when the chamber is vented.
Functional verification
From Reputed Manufacturers
TENDER FOR Electron Beam Welding machine
Page 24 of 34
Sl. No. Indicated Specifications Description Inspection type
B. 12. Viewing and Beam
Alignment
1. Coloured camera to achieve 10X
magnification at shooting distance from 50-
300mm inside chamber (From top to bottom
of the chamber).
2. Video to be displayed on HMI-PC.
3. Binoculars Viewing system for manual
focussing to be provided for both EB guns.
4. Provisions for aligning the joint with beam
before welding and during welding.
5. Suitable vapour protection for optics (like
stroboscopic system).
6. A cross hair shall be superimposed over the
image to allow the position of the beam on
the joint to be precisely adjusted before
welding.
7. Seam tracking by teach in & replay system by
interpolation.
Physical and
functional
verification
C. Welding Chamber
1. Material Non-magnetic Stainless steel Physical
verification
2. Width x Length x Height 305mm x 305mm x 305mm or better Physical
measurement
3. Wall thickness The thickness of the chamber walls shall be
designed to block X-ray radiation in accordance
with international regulations.
(<1μSv/h measured 100 mm from the walls)
Functional
verification at
OEM's place
by third party
inspection
4. Front access door Access door shall have hinged and open towards
the left of the welding chamber when viewed
from the front of the machine.
Physical
verification
5. View port Viewing port Ø150mm lead glass and vapour
protective removable glasses for easy
replacement shall be located centrally on the
front door.
Physical
verification
6. Sealing System 1. Sealed door, Access ports and Pumping
system with leakage ≤ 10-6 mbar.l/s.
2. Suitable leak detection ports to be provided.
3. Door ,Access ports and Pumping system
shall have suitable compatible O ring Seals.
Functional
verification.
TENDER FOR Electron Beam Welding machine
Page 25 of 34
Sl. No. Indicated Specifications Description Inspection type
C. 7. Chamber vacuum
pumping
The Welding chamber shall have separate
vacuum pumping system with following
specifications.
NOTE: The entire vacuum
components/pumps/valves of the gun shall be
from the same source/manufacturer
(Viz. Edwards, Leybold, Agilent & Pfeiffer.)
Physical
verification
7.1 Working Vacuum
level
10-4 mbar or better Functional
verification
7.2 Vacuum suction
time
Less than 4 minutes Functional
verification
7.3 Ultimate vacuum
level and duration
5X10-5 mbar or better in
less than 5 minutes
Functional
verification
7.4 Pumps 1. One Rotary pump.
2. One Roots pump.
3. One Turbo
molecular pump with
safety interlocks .
4. One rotary backup
pump for Turbo
molecular pump.
5. Valves
Physical
verification
7.5 Vacuum
Measurement and
instrumentation.
Vacuum measurement by Pirani/Penning/Wide
range gauge. (Gauge/s make and model to be
mentioned in the technical offer)
Note: Suitable provision shall be made for leak
detection in vacuum pumping line with leak
detection ports.
Functional
verification
7.6 Over-ride Manual override provision for vacuum pumps
and valves through HMI.
Functional
verification
From Reputed Manufacturers
TENDER FOR Electron Beam Welding machine
Page 26 of 34
Sl. No. Indicated Specifications Description Inspection type
D. Work Handling System
1 Configuration 1. CNC controlled X and Y Table mountable
on to chamber bottom with suitable
arrangement for accurate fixturing.
2. Vertical Rotary manipulator with
arrangement to swap in the place of XY
table. This manipulator is mounted
externally, on the bottom side of the working
chamber.
3. Horizontal Rotary manipulator mounted
externally, on the left of working chamber
when viewed from front of the machine.
With Following Specifications,
NOTE: All the components of work handling
system are made of Non-magnetic material.
Physical
verification
Replacement
of Vertical
manipulator by
XY table and
accurate
clamping to be
demonstrated
2. X Y Table Physical
verification
2.1 Table size 150mm X 150mm or better Physical
measurement
2.2 Stroke length 3. X-axis : 100mm to 200mm
4. Y-axis : 100mm to 200mm
Physical
measurement
2.3 Accuracy 3. X-axis : 50 µm or better
4. Y-axis : 50 µm or better
Physical
measurement
2.4 X. and Y. Speed 1-2000mm/min or better
Physical
measurement
2.5 Load carrying
capacity
Up to 20 kg.
Physical
verification
3 Horizontal and Vertical
Rotary Manipulators
The Rotary manipulator shall have axis accuracy
of 100μm. The rotary manipulator shall have
centrally sliding hardened shaft with proper
vacuum seal, moves inside and outside of the
vacuum chamber and provision to mount the
chuck inside the vacuum chamber.
Physical
measurement
3.1 Shaft Size 25mm diameter x 450mm long hardened non
magnetic shaft.
Physical
measurement
TENDER FOR Electron Beam Welding machine
Page 27 of 34
Sl. No. Indicated Specifications Description Inspection type
D. 3. 3.2 Positioning for
Welding
Fully hardened collet clamping. Physical
measurement
3.3 Diameter of
chuck
Non magnetic High precision 70mm three jaw
self aligning chucks.
Physical
measurement
3.4 Rotating Speed Rotary speed adjustable from 1rpm to 60 rpm.
Physical
measurement
3.5 Speed stability ±1% of set speed Functional
verification
3.6 Spindle Run-out 30µm or better Physical
measurement
3.7 Drive system Servo Motor (CNC controlled) Functional
verification
3.8 Loading Capacity 20 kg or better Physical
verification
E. High voltage power
supply
High voltage power supply shall be with switch
mode power supply, variable bias supply for
beam current control with an adjustable and
stabilized supply for filament heating and it shall
have following features.
1. The power supply shall have ANTI-FLASH
protection.
2. Less power dissipation.
3. High voltage proof.
4. Short circuit proof (supply needs to switch
off to avoid mis-welding and loss of
expensive work piece)
5. Zero beam current during HV recovery
(Defocusing of beam to avoid miss welding
and loss of expensive work piece)
6. Oil filled tanks and top lid easily removable
for maintenance.
Physical
verification
TENDER FOR Electron Beam Welding machine
Page 28 of 34
Sl. No. Indicated Specifications Description Inspection type
F.
Control System
1 Configuration The control system to be based on Industrial
PLC, industrial HMI (Human Machine
Interface), a PC and numerical control system
which shall be of latest windows based CNC
system. The PC shall be equipped with at least
• 2 Nos. of USB ports, • 2 Nos. of serial ports • 2 Nos. of Ethernet ports.
Physical
verification
2. PLC The industrial PLC working with industrial
HMI-PC supervisory system with GUI shall be
able to control following parameters of Electron
Beam Welding Machine :
1. Welding chamber vacuum Sequence. 2. Electron gun Vacuum Sequence . 3. Electron gun Isolation valve control. 4. Electric supply of gun. 5. Safety interlocks/Security system 6. CNC Interface. 7. Alarms and Security. 8. Auto Diagnostic for Maintenance.
Functional
verification
3. PC supervisory system CNC system shall work with industrial PC,
providing the operator interface in dialog mode
with an industrial HMI (Human Machine
Interface) standard supervisor system. The
supervision program uses standard software on
latest version of Windows. It shall be responsible
for the overall management of the machine, in
particular:
1. Management of start-up modes: immediate
or deferred.
2. Management of gun settings, including
conditioning and space charge.
3. Management of the video and cross-hairs.
4. The displays of pump units, power supplies
for the gun, mechanical movements etc.,
5. Management of faults, with history.
6. Tracking the duration of use of various
components, including cathode counter
(hours), filament, pumps, etc., in order to
facilitate preventive maintenance.
7. Troubleshooting with access to each PLC
input/output variable.
Functional
verification
TENDER FOR Electron Beam Welding machine
Page 29 of 34
Sl. No. Indicated Specifications Description Inspection type
F.
4 CNC system The welding programs shall be managed by
CNC system with the following specifications :
1. Fitted with a dedicated keypad and screen.
2. The welding programs shall be created,
executed and stored by CNC system
working to meet the requirements of
standards such as ISO 14744.
3. The control system shall include hand held
pendant with electronic hand wheel and
foot switch for precise adjustment of the
CNC axes in manual mode and necessary
controls for machine operation.
4. Programming language shall meet the
standards such as ISO.
5. Supervision program shall be with standard
software on latest version of Windows
based operating system.
6. Control of mechanical welding axis and
the electrical settings for the beam
(accelerating voltage in kV, beam current in
mA, focus current in mA, X and Y beam
deflection amplitude in A), linear speed in
X and Z axis(Gun axes) & XY table axes in
mm/min, rotary speed in rpm and mm/min.
7. The welding programs include all the data
required to carry out the full welding cycle.
The complete welding program shall be
able to set ramp up, dwell time, ramp down.
8. Program storage capacity in CNC memory
– minimum 10 programs and mass storage
with PC hard disk shall be a minimum of
100GB.
9. Programs can be downloaded from the
supervisor PC. The PC's hard disk shall
serve as mass storage in the event that a
large number of programs are used.
Functional
verification
TENDER FOR Electron Beam Welding machine
Page 30 of 34
Sl. No. Indicated Specifications Description Inspection type
F.
5 Parameters display Following operating parameters shall be
displayed at the control panel:
1. Display for vacuum level in welding
chamber and gun in mbar.
2. Speed and position of manipulators and X-Y
axes Table.
3. Speed and position of gun movement.
4. Accelerating voltage.
5. Beam current.
6. Focus current.
7. Beam deflection signal (by oscilloscope).
8. Indicators for diffusion pump ready.
9. Audio-visual display (Alarm) for air/water
failure.
10. Programming with HMI (Human Machine
Interface) shall include mimic display, alarm
status, quality data recording, error
indicators, operation screen for tooling,
vacuum and weld cycle recipes.
11. Programs shall be linked to build up a fully
automatic program consisting of tacking,
penetration, cosmetic pass, deflection,
stirring, etc.
Functional
verification
G. Safety 1. Radiation levels to be measured in
accordance with the ISO standard-14744 or
equivalent standards.
2. The chamber shielding shall ensure radiation
levels of less than 1µSv/hour, at a distance
of 100mm from any external surface, with a
defocused beam of maximum power.
3. Radiation shield in the equipment shall meet
the requirement of annual whole body dose
limit of 50 mSv (maximum)
4. Illumination of red warning light when the
high voltage to the gun is on.
5. Water flow, water temperature and air
pressure switches to protect the vacuum
pumping system against power supply
failure. Audible warning of failure should be
provided.
Functional
verification
along with
third party
inspection
wherever
necessary.
TENDER FOR Electron Beam Welding machine
Page 31 of 34
Sl. No. Indicated Specifications Description Inspection type
G. Safety 6. All rotary drives shall be fully protected by
safety guards and noise from the machine
shall be less than 70 dB.
7. Safety interlocks for preventing accidental
energizing of high-voltage without required
vacuum level, opening of isolation valve
etc., shall be incorporated.
8. Beam shall not be “ON” without sufficient
vacuum in gun and chamber.
9. System shall have automatic trips for over
kV, over mA, filament failure and auto-
diagnostic system.
H. Online data monitoring and storage
This system shall be fitted with the equipment and shall have the following features: The system shall have a minimum number of channels and allows storing of the data of the actual welding parameters as well to plot the curves for each parameter all along the welding cycle. PC shall be equipped with a software program to record the welding data with a minimum sampling interval of 0.05 seconds. The data recorded for each weld shall be provided in an Excel spreadsheet. The following parameters are to be recorded, 1. Accelerating voltage (kV). 2. Beam current (mA). 3. Focus current (mA). 4. Linear Gun table speed (m/min). 5. X Y table welding speed (mm/min) 6. Rotary welding speed (rpm). 7. Vacuum level in gun & chamber (mbar).
Functional verification
I. Cooling System Suitable closed loop water cooling system indicating the temperature, flow rate, power etc.
Physical verification
J. Input Electrical Supply Voltage: 415±10% Three phase and Neutral Power: 25 kVA±10% Frequency : 50Hz ± 1% Earth: ≤ 2Ω
Functional Verification
K. Test data and Documents for Electron Beam Welding machine
All test data shall be recorded along with detailed checking of beam
equipment functions and components
1 Instruction manual Physical
verification
TENDER FOR Electron Beam Welding machine
Page 32 of 34
Sl. No. Indicated Specifications Description Inspection type
K. 2 Maintenance manual Physical verification
3 Diagrams for
all mechanical assemblies
with parts lists.
Physical verification
4 Mechanical,Electrical and
Electronic diagrams
Physical verification
5 Technical documentation
for the main components
purchased.
Physical verification
6 Original licence for the
software which is
purchased.
Physical verification
7 One soft copy of all
the manuals and diagrams
in PDF format,
as well as the
specific programs
(PLC and man-
machine interface).
Physical verification
8 One re-
installation CD for the PC
Physical verification
9 Licensed version software
CD and replaceable hard
disk installed with all the
software shall be
included.
Physical verification
10 Calibration certificate for
all the vacuum gauges
shall be provided
Physical verification
11 Spare parts list with
source of supply and
prices
Physical verification
12 The supplier should
provide details regarding
the safety measures
adopted in the system.
Physical verification
13 Manuals of bought out
items incorporated in the
system
Physical verification
TENDER FOR Electron Beam Welding machine
Page 33 of 34
Sl. No. Indicated Specifications Description Inspection type
L Safety and
Certifications
All the necessary safety regulations such as CE
compliance, low voltage directives, EMC
regulations compliance details, Alarms and
emergency switch-off in case of any
malfunctioning must be provided. The system
must be equipped with all the necessary safety
interlocks.
M Warranty - inclusive of
parts and labor
The complete system and its associated hardware / software should have a standard warranty of 24 months from the date of installation, commissioning and acceptance of the system at CMTI.
Maintenance/ repair /replacement of any hardware or software component of the system during warranty period to be done free of cost (including expenses of Engineer from OEM) .
Supplier modification(s) / Software upgrades shall be intimated and same will be made available free of cost during the warranty period.
Spares list required and their cost for 2 years of operation after the warranty period shall be indicated in the offer.
Additional 12 months extended warranty may be
quoted as an option.
N Annual Maintenance
Contract
AMC per year basis and on bulk basis (for 3
years) including parts and labor to be quoted
separately. The terms, Conditions and amount
payable for AMC should be provided by the
vendor which shall include,
1. Preventive Maintenance
2. Breakdown Maintenance
Note: AMC terms and conditions shall be agreed
upon mutually before placement of Purchase
Order
TENDER FOR Electron Beam Welding machine
Page 34 of 34
Note:
1. The final Acceptance Criteria will be based on mutual agreement and will be
finalized at the time of placing the order. The equipment will be finally accepted
based on the compliance of the equipment with the Acceptance Criteria. Hence, the
bidder has to go through the Acceptance Criteria and convey their acceptance
unambiguously. They may also suggest a suitable method of verification if the
proposed method is not acceptable to the bidder.
2. Bidders are to provide technical specifications as per following guidelines.
Technical bid shall consist of
a. Index of items
b. Compliance Matrix
c. Machine Brochure - incorporating machine technical specifications.
d. Technical details or datasheets of all third party machine elements (pumps,
gauges, valves etc.)
e. List of certificates and documents along with quantity that will be provided
with the machine.
f. Complete list of spares for 2 years of operation.
g. Detailed Address of Indian service provider (if any) with Contact person
Name, email ID and Phone No.
h. Detailed Address of OEM with Contact person Name, email ID and Phone
No.
The above documents have to spiral bound. In Order, preferably as above.