Annexure - I Page 1 of 21 SPECIFICATIONS OF TOW CABLE ASSEMBLY (TCA‐ UC) 1. Introduction The Tow Cable Assembly is the Wet‐end of a Towed Array Sonar System which aids in the deployment/ retrieval of a linear Towed Sensor Array with the help of a Sonar Winch. The scope of the present procurement is Fabrication, Assembly, Testing and Supply of 2 sets of Tow Cable Assembly (TCA‐UC). The Tow Cable Assembly consists of Heavy Tow Cable (HTC) and Light Tow Cable (LTC) joined together by seamless technology called Electro‐Optic‐Mechanical tow cable Inter connector (EOMIC). The free end of the HTC is provided with a winch end mechanical termination and optical conectorisation. The free end of the LTC is to be assembled with Cable Interface Module(CIM) the function of it is to convert the electrical signal from Towed Sensor Array into optical signal. The details of the EOMIC and CIM are explained in the sections given below. A schematic block diagram is shown below. Fig 1 . Schematic block diagram of Tow Cable Assembly 1. Heavy Tow Cable (HTC)– 535 m 2. EOMIC 3. Intermediate Anchoring 4. Light Tow Cable(LTC)‐ 200m 5. Cable Interface Module 2. Scope of Work Scope of Work C/NC The work involves Fabrication, Assembly, Testing and Supply of 2 sets of “Tow Cable Assembly (TCA‐UC).” as per details in the tender document 2.1 Procurement of all components except Free Issue Materials (provided by NPOL), Assembly, Fabrication of Sub‐Systems, Inspection/Testing as per Specification. 2.2 Fabrication of all fixtures necessary for the Fabrication, Assembly, Testing and Supply of “Tow Cable Assembly (TCA‐UC)” at each stages of Production. 2.3 Fabrication of all components for Bend Restrictor Moulding and procurement of raw materials required for moulding. 2.4 Final inspection and testing of the “Tow Cable Assembly (TCA‐UC)” as per NPOL documents. These documents will be provided on finalization of contract. 1 3 2 5 4
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Annexure - I
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SPECIFICATIONS OF TOW CABLE ASSEMBLY (TCA‐ UC)
1. Introduction The Tow Cable Assembly is the Wet‐end of a Towed Array Sonar System which aids in the deployment/ retrieval of a linear Towed Sensor Array with the help of a Sonar Winch. The scope of the present procurement is Fabrication, Assembly, Testing and Supply of 2 sets of Tow Cable Assembly (TCA‐UC). The Tow Cable Assembly consists of Heavy Tow Cable (HTC) and Light Tow Cable (LTC) joined together by seamless technology called Electro‐Optic‐Mechanical tow cable Inter connector (EOMIC). The free end of the HTC is provided with a winch end mechanical termination and optical conectorisation. The free end of the LTC is to be assembled with Cable Interface Module(CIM) the function of it is to convert the electrical signal from Towed Sensor Array into optical signal. The details of the EOMIC and CIM are explained in the sections given below. A schematic block diagram is shown below.
Fig 1 . Schematic block diagram of Tow Cable Assembly
1. Heavy Tow Cable (HTC)– 535 m 2. EOMIC 3. Intermediate Anchoring 4. Light Tow Cable(LTC)‐ 200m 5. Cable Interface Module
2. Scope of Work
Scope of Work C/NC The work involves Fabrication, Assembly, Testing and Supply of 2 sets of “Tow Cable Assembly (TCA‐UC).” as per details in the tender document
2.1 Procurement of all components except Free Issue Materials (provided by NPOL), Assembly, Fabrication of Sub‐Systems, Inspection/Testing as per Specification.
2.2 Fabrication of all fixtures necessary for the Fabrication, Assembly, Testing and Supply of “Tow Cable Assembly (TCA‐UC)” at each stages of Production.
2.3 Fabrication of all components for Bend Restrictor Moulding and procurement of raw materials required for moulding.
2.4 Final inspection and testing of the “Tow Cable Assembly (TCA‐UC)” as per NPOL documents. These documents will be provided on finalization of contract.
1 32 54
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2.5 Documentation of all progress activities.
2.6 Documentation of Limited Qualification Tests, Inspection and Test reports
NOTE: FILL C – FULLY COMPLIED AND NC – NOT COMPLIED
3. Deliverables
Deliverables 1. 2 sets of “Tow Cable Assembly (TCA‐UC)” 2. Documents of Stage Inspection & Final Inspection
4. Delivery Schedule
Delivery Schedule C/NC The delivery schedule of 1st set of “Tow Cable Assembly (TCA‐UC)”shall be 2 months from the date of placement of order. The delivery schedule of 2nd set of “Tow Cable Assembly (TCA‐UC)”shall be 4 months from the date of placement of order.
NOTE: FILL C – FULLY COMPLIED AND NC – NOT COMPLIED
5. Free Issue Materials Following items will be supplied by NPOL for each set of Tow Cable Assembly (TCA‐UC).
S.No. Item Description Qty Unit
1 Heavy Tow Cable 535 m
2 Light Tow Cable 200 m
3 Test Projector Housing 1 No
4 PU Tube 10 m
5 Kevlar Tape 10 m
Note: The above materials are to be assembled inside NPOL premises and are not allowed to take it
out from NPOL.
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6. Brief Specifications of EOMIC and CIM
6.1 EOMIC The Electro‐Optic‐Mechanical tow cable Inter connector (EOMIC) is a flexible cylindrical module at the wet end system which links the light tow cable and heavy tow cable. The module is subjected to the tensile loads due to hydro dynamic drag, the compressive loads at the fairlead during deployment, the bending loads during winding on winch drum and the hydro static pressure due to the operating depth. Further the unit is also subjected to the fluctuating loads due to the dynamics of sea and ship motion. The functional requirements of EOMIC are listed below.
a) Mechanical interface between Heavy Tow Cable (HTC), Light Tow Cable (LTC).
b) Inter‐connection of electrical and fiber optic lines of HTC and LTC.
The EOMIC consists of following 4 major sub–assemblies.
1. Heavy Tow Cable (HTC) termination.
2. Light Tow Cable (LTC) termination with 12 pin square flange connector.
3. Wire rope (strength member) loop assembly.
4. Fiber optic Splice protector assembly.
Table 1 shows the electrical, optical and mechanical specification for EOMIC.
Note: The specifications Sl. No. 1 to 8 corresponds to M/s Uniflex make Heavy Tow Cable (2011 make) and Light Tow Cable (2011 make) available at NPOL. 6.1.1 Pre‐Assembly steps for EOMIC
Following steps are prerequisites for carrying out EOMIC assembly. a) Visual inspection and dimensional checks of HTC and LTC cables – cross sectional
dimensions of individual sections to be checked and noted for reference.
b) Electrical and optical health check of the cables.
c) Winch end termination on free end of HTC.
d) Transfer HTC to a drum/ winch to bring out EOMIC end of HTC on outer layer and cut the steel armour of HTC to specified length.
e) Transfer LTC to a drum with 20m of innermost layer accessible for Cable Interface Module(CIM) Assembly. Cut polymer armour of LTC to specified length from the EOMIC end.
Note: The details will be provided only at the time of clarification in person at NPOL or placement of contract to prospective vendors visiting NPOL to know the content of work and hence estimate the cost prior to the Tender Opening date. Offers received otherwise will not be considered.
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6.1.2 Assembly procedure for EOMIC The Assembly of EOMIC involves the following steps. a) HTC Armour Termination at EOMIC HTC end and testing.
b) Assembly of Intermediate Anchoring on LTC.
c) LTC Armour Termination and testing.
d) Assembly of Strength member ( Wire rope assembly).
g) Assembly of PU (PolyUrethane) hose and gel filling.
Note: The details of all the steps (from a to g)will be provided only at the time of clarification in person at NPOL or placement of contract to prospective vendors visiting NPOL to know the content of work and hence estimate the cost prior to the Tender Opening date. Offers received otherwise will not be considered.
6.1.3 Acceptance Test procedure for EOMIC assembly The EOMIC assembly experiences axial forces during towing, hydrostatic pressure and
dynamic loads during deployment and retrieval. The following tests are to be conducted to
ensure the smooth functioning of EOMIC meeting all the specifications. These tests are
mentioned in the assembly procedure in the preceding sections.
6.1.3.1 Load tests
Objective ‐ Load tests are done to check the mechanical strength of EOMIC so as to ensure
that EOMIC withstands actual towing load.
6.1.3.1.1 Tests prior to assembly of EOMIC – Proof load tests are to be conducted as per
following scheme. The test equipments like Load cell, Chain Pulley Block etc required for
load testing is the scope of the vendor.
Table 2 ‐ Load tests prior to the assembly of EOMIC
Sl No. Item Aim Test Machine 1. HTC termination Proof load test of 5T Chain & pulley block2. LTC termination Proof load test of 3T Chain & pulley block
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3. Intermediate Anchoring Proof load test of 3T Chain & pulley block
4. Wire rope single piece Break load test of 7T At Bharath Wire Ropes, Mumbai
5. Wire rope Assembly (NPOL Dwg no. 232 37 042)
Proof load test of 5T for 15 minutes
At Bharath Wire Ropes, Mumbai
6.1.3.1.2. Deployment Simulation test The schematic of the test set up is given in Fig 2. The flexible assembly ( EOMIC –
Intermediate Anchoring portion) to be wound on winch drum and passed through the
rollers for a load of 1 ton for 10 cycles by creating the actual deployment angle of 15°‐25°.
Optical line continuity to be monitored during tests. Electrical and FO continuity checks to
be carried out to ensure continuity of power lines, signal lines, and optical lines. The details
will be provided as Apppendix 1 & 2.
Dimensional checks to be conducted on overall size – length and diameter before
and after the test. Visual inspection to be conducted on PU for presence of cracks/ abrasion/
puncture. Hose should be free of cracks/abrasion. The test facility will be provided at NPOL.
The conduct of the test is the responsibility of the vendor.
Fig 2 Schematic view of Deployment/Retrieval simulation test setup
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The following Details will be provided at the time of clarification in person at NPOL or
placement of contract
Appendix 1 : Test Specifications for Heavy Tow Cable Appendix 2 : Test Specifications for Light Tow Cable Appendix 3 : Procedure for preparation of Polyurethane potting compound Appendix 4 : Fiber Optic Splicing Appendix 5 : LTC & HTC – Interface Connections Appendix 6 : General precautions Appendix 7 : Polyurethane Carbon Fiber Composite Bend Restrictors for Towed Array System Appendix 8 : Bend restrictor for Intermediate Anchoring on aft end Appendix 9 : Procedure for fabrication of Rubber over molding Appendix 10 : List of Reference Drawings Note: The above details/drawings will be provided only at NPOL for the purpose of cost estimation. Only hard copy will be provided at the time of clarification in person at NPOL or placement of contract. Vendors will not be permitted to take the drawings out of NPOL on any accounts)
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6.2 Cable Interface Module
Cable interface module interconnects Towed Sensor Array and tow cable, mechanically
and electrically. Cable interface module houses the electronics required to transfer the array
data over the tow cable to onboard. The Ethernet data from the Towed Sensor Array reaches
the Cable interface module as two separate Ethernet links for transferring the array data over
the tow cable.
The CIM has got two physical section namely rigid portion and flexible portion. The rigid
portion houses the LEDs of the Media converters and is the interface with Tow cable. The
flexible portion houses PCBs of media converters, Ethernet to VDSL2 converters, three port
Ethernet switches and DC‐DC converters and interfaces with array. A hydrophone housing
carrying an insonifying transducer(Test Projector Housing) is also incorporated in the flexible
portion of CIM.
Fig3. Block Diagram of Cable Interface Module 1. Light Tow Cable 2. Rigid module 3. Flexible Module 4. Media Converter Electronics 5. Media Converter PCB Housing 6. Test Projector Housing 7. Dual Power Converter Housing 8. Ethernet Switch Capsule 9. VDSL PCB Capsule 10. Electro‐mechanical Connector
10 5 6 7 8 9 9 84 1
2
5
3
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The Table 3 given below shows the Technical Specifications of Cable Interface Module (CIM)
Technical Specifications of CIM C/NC
Module Length(exclusive of Cable) : 4 meters
Module diameter : 80 mm
LTC length(Free Issue Material) : 200 m
Polyurethane tube : 3 meters
KEVLAR Tape : 12 meters
End connector(Part No. UWNRV‐28‐P6‐P&S‐2CX) : Socket at the free end
This module houses the following
a) Power Supply Capsule +5 V : 1 Nos.
b) Power Supply Capsule +8V : 1 Nos.
c) Ethernet Switch : 4 Nos.
d) VDSL2 PCB Housing Assembly : 2 Nos.
e) Media Converter PCB Housing Assembly : 4 sets
f) Mechanical Components for CIM Assy(Rigid portion) : 1 set
Wiring, Assembling and Testing of CIM as per TOT which will be provided at the time of placement of contract
NOTE: FILL C – FULLY COMPLIED AND NC – NOT COMPLIED
Note: The details of the Wiring, Assembling and Testing will be provided only to prospective vendors visiting NPOL to know the content of work and hence estimate the cost prior to the Tender Opening date. Offers received otherwise will not be considered.
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7. TERMS AND CONDITIONS Terms and Conditions C/NC
7.1 Assembly of the Tow Cable Assembly (TCA‐UC) should be carried at NPOL
premises directly by the vendor. Outsourcing of assembly related work is
not accepted.
Only floor space will be provided to the vendor for carrying out the
work except Deployment Simulation Test & Vibration Test facility as
mentioned in the Annexure 1. Cable drums required for transferring is to
be arranged by the vendor.
7.2 Vendors with minimum 3 years prior experience (With in the recent past
5 years) in Integration of Electrical, Optical, and Mechanical
interconnection using pressure balanced flexible module between steel
armoured electro optical mechanical heavy tow cable and polymer
armoured electro optical mechanical light tow cable for defence
undersea application only would be considered. Certificates/Copy of
supply orders to prove the same to be attached along with the Technical
bid. Offers without proof of prior experience will be summarily rejected.
The vendor should hold the same price for the “Tow Cable Assembly
(TCA‐UC)” for 3 more years.
7.3 The Vendor shall carry out Qualification tests as per DQAN guidelines.
Environmental Stress Screening (ESS) Tests include Thermal Shock, Random
vibration and Endurance/burn‐in for 100% Electronic Components. The
Environmental Tests (ET) includes High temperature storage test and Vibration
test as per MIL‐STD‐167‐1(Ships). Details of these tests shall be provided in the
TOT document at the time of placement of contract.
7.4 All equipment necessary for development and testing of system will be the
responsibility of the Vendor. The following testing equipment has to be
arranged by the Vendor for carrying the testing work.
a) Optical Time Domain Reflectometer(OTDR) to check the health of
the optical lines in the tow cables.
b) Computer/ Laptop with 100 Mbps Ethernet port loaded with Lab ‐
view software (preferably latest version)
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c) Function ( Arbitrary Waveform ) generator(10 MHz)
d) 100 MHz Digital storage oscilloscope.
e) High Voltage (300V/2 kW) DC power supply, with UPS back up
f) Regulated DC power supply 0 – 30V, 5A
g) 1000 V Megger
h) RMS Multimeter
7.5 Stage inspection for all parameters specified by NPOL will be the Vendor’s
responsibility. However NPOL reserves the right to carry out progress review
and inspection at any stage of work. All measured values as indicated in the
assembly and inspection procedures have to be recorded and be made
available for verification by NPOL.
7.6 Vendor should submit a production schedule and quality plan along with
the quote (technical bid). Detailed plan for the execution of development work
and quality tests shall be submitted along with the offer itself. Otherwise the
offer is liable to be rejected.
7.7 Progress of work will be regularly monitored by NPOL reps. A Progress
Review Committee (PRC) constituted by Director, NPOL, Kochi‐21, will review
the progress, suggest alternate course of action if any at a regular interval. The
vendor has to depute appropriate personnel to attend the same.
7.8 No NPOL manpower will be provided to facilitate the Fabrication,
Assembly, testing and Supply of Tow Cable Assembly(TCA‐UC)
7.9 No deviation is permitted in the assembly procedures laid out by NPOL.
7.10 No alternative design submitted by Vendor is acceptable or permitted.
No clarification regarding this will be considered.
7.11 Failure of development of system at any stage of manufacture will be
the responsibility of Vendor. No compensation will be provided by NPOL for
partly completed work.
7.12 Detail drawings, wiring diagram, assembly procedure and ATP will be
provided from NPOL on placement of contract. Any design detail other than
that required for system development will not be provided.
7.13 NPOL or its nominated agency will carry out the final Inspection of the
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finished product Tow Cable Assembly(TCA‐UC) at NPOL as per ATP. The
vendor shall arrange the documents relevant for the Factory Acceptance Tests
[FATs]. Necessary assistance and test facilities to conduct testing shall be
provided by the vendor.
7.14 Finished product have to be packed in a Cable Handler(made of mild
steel and painted with corrosion free paint) with a minimum bending
diameter of 1 m. Design of the Cable Handler and supply is the scope of the
vendor. The Vendor should get the design clearance before proceeding for
fabrication of the Cable Handler.
7.15 Any clarification can be done prior to submission of bid. Clarification
should be requested to Director NPOL, clearly referring the tender enquiry
number. The vendor should clearly mention the contact number and contact
person at his end for NPOL to get back to the specific query.
7.16 The vendor should provide Warranty for the “Tow Cable
Assembly(TCA‐UC)” for a period of 1 Year from the date of inspection and
acceptance at NPOL. The warranty shall be repair/ replacement of parts of
EOMIC and CIM.
7.17 Payment will be in Indian Rupees only. Payment shall be on pro‐rata
basis.
7.18 The design of Tow Cable Assembly (TCA‐UC) is the sole property of
NPOL. The contractor shall not disclose any information regarding the Tow
Cable Assembly(TCA‐UC) without written permission of NPOL. A relevant
clause will be included in the contract.
7.19 The vendor’s technical competence, managerial capabilities and
financial status will be assessed by a team of Officers of NPOL to ascertain the
Company’s capability to complete the given work within the specified time
period.
Appropriate weightages shall be assigned to each criterion and finally marks
will be assigned on a 10 point scale. A cut‐off of 6 out of 10 will considered for
qualifying the vendor.
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7.20 Only Indian nationals will be allowed to participate in meetings at
NPOL in connection with this tender document.
7.21 Prospective vendors are to visit NPOL and be acquainted with the
development work against this tender document before submission of techno‐
commercial offer (before the tender opening date). This is a mandatory clause
for the vendors. Offers received otherwise will be summarily rejected.
The vendor should assess the quantum of work and manufacturing costs of
components details of which will be provided only at NPOL before tender
opening date and will not be allowed to carry the information outside NPOL.
7.22 Vendor has to enclose a Signed Specification Compliance Sheet given
in Section 8 of Annexure 1. Vendor has to accept all specification mentioned in
the Specification compliance sheet. Specification compliance sheet to be
attached in technical bid.
7.23 The vendor shall also indicate the cost in the Price bid format given in
Section 9.1 of Annexure 1. The same format without price may be enclosed in
the technical bid.
7.24 Breakup cost for individual modules shall be also given as per the
Cost Break up format given in Section 9.2 of Annexure 1 in the price bid. The
same format without price may be enclosed in the technical bid.
7.25 All documents relating to “Terms and conditions” should be
enclosed in the ‘Technical Bid’ part of tender document.
NB: Bid will be accepted only if all the above terms and conditions are met. The
terms and conditions mentioned above are for technical compliance. The terms
and conditions in tender document are applicable over and above these.
NOTE: FILL C – FULLY COMPLIED AND NC – NOT COMPLIED
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8. SPECIFICATION COMPLIANCE SHEET
This sheet has to be attached along with the technical bid with signature, seal of the
company and compliance.
SPECIFICATION COMPLIANCE SHEET
S.No Specification C/ NC Remarks 1 Procurement of all components as per the Bill of materials (Section 10)
of Annexure 1 provided by NPOL. Custom developed and Type approved components will not be changed. No alternate components are acceptable
2 Testing of all procured components as per NPOL ATP
3 Fabrication of Mechanical Components from recommended vendors as per BOM/NPOL Drawings
EOMIC
4 Pre‐Assembly steps for EOMIC as per specification
5 Assembly procedure for EOMIC as per specification
6 Acceptance Test procedure for EOMIC assembly as per specification
a) Load Tests prior to assembly of EOMIC b) Deployment simulation test
CIM
7 Assembly of PCB’s in their housings as per NPOL Specification 8 Assembly of Sensors in their housings as per NPOL Drawing
9 ESS of the Electronic Components as per TOT by NPOL to be provided along with contract
10 System wiring as per NPOL wiring Scheme
11 Assembly of system into flexible tube, Oil/gel filling, sealing as per
NPOL assembly document
Towed Cable Assembly(TCA‐UC)
12 Inspection of Towed Cable Assembly(TCA‐UC)as per NPOL ATP
13 Documentation of all progress activities
14 Documentation of Inspection and Test reports
15 Documentation of all Limited Qualification tests
17 Final Inspection of Towed Cable Assembly(TCA‐UC)at NPOL jointly with
the vendor
18 Visited NPOL and was acquainted with the development work against
this tender document before submission of techno‐commercial offer
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19 The design of Towed Cable Assembly (TCA‐UC) is the sole property of
NPOL. The contractor shall not disclose any information regarding the
Towed Cable Assembly (TCA‐UC) without written permission of NPOL.
A relevant clause will be included in the contract.
20 We meet all “terms and conditions” enclosed
NOTE: FILL C – FULLY COMPLETED AND NC – NOT COMPLIED
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9. PRICE BID FORMAT
9.1 Price Bid: The quotation should be in the format provided below and has to be enclosed
in price bid only. A copy of the quotation without price is to be enclosed in technical bid.
FORMAT ‐ PRICE BID
S.No Item Description Quantity Total Amount (Rs)
Remarks
1 Fabrication, Assembly, Testing and Supply of Tow Cable Assembly (TCA‐UC) as per specifications in Annexure 1.
2 sets
2 Applicable Taxes
Total Cost
9.2 Cost break up: The quotation should also be provided in the format provided below and
has to be enclosed in price bid only. A copy of the quotation without price also has to be
enclosed in technical bid.
FORMAT – MODULE COST BREAKUP
Cost Break up for Tow Cable Assembly(TCA‐UC)
S.No Item Description Material Cost
Man power Cost
Integration &Testing Charges
Module Basic Cost
1 Electro Optic Mechanical Inter Connector(EOMIC)
2 Cable Interface Module(CIM)
Any other charges other than taxes
Total Cost of 1 set of Tow Cable Assembly (TCA‐UC)
‐ ‐ ‐
NB:
The vendor has to clearly indicate separately the applicable taxes for the order.
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10. Bill of Materials for EOMIC and CIM 10.1 Bill of Materials for EOMIC The following are the bill of materials required for the assembly of 1 set of EOMIC. (The details will be provided only at the time of clarification in person at NPOL)
SL. No. DRAWING No. ITEM DESCRIPTION MATERIAL QUANTITY
