Specifications of Whap Hull

8/13/2019 Specifications of Whap Hull

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.Technical Specifications for Manufacturing of hull and integrationof Automotive & Non-automotive aggregates for WHAP

(No. VRDE/WV/WHAP/HULL/811 Dt. 21stFeb 2013)

1. BACKGROUND

VRDE is developing state of the art Technology Demonstrator Wheeled Armoured

Platform called WHAP. WHAP is a multi utility armoured platform with modular

design, configurable for variety of combat and combat support roles upto 26 ton

GVW. It consists of a monocoque blast protected hull envelop with a combination of

high hardness steel and add-on composite armour to provide scalable protection.

WHAP is powered with a high power diesel engine and is equipped with 8x8driveline with independent suspension. WHAP is designed for amphibious operation

upto a GVW of 22.5 ton.

Following document outlines the work package for execution of manufacture and

total assembly / integration of automotive / non-automotive aggregates of the

prototypes.

2. INTRODUCTION

The following paragraphs describe the specifications and general requirements of

manufacturing of armoured Hull system of WHAP and assembly of Automotive /

non-automotive aggregates on the Hull System. One bare hull will be manufactured

by DA (Development Agency) which will be used for blast testing by VRDE prior to

the manufacture of two prototypes of WHAP which will be rolled out from the DA

premises. The complete work package consists of manufacturing, design and

development of certain systems, assembly of automotive and non-automotive

aggregates, testing, documentation, association with trials and provision of spares.

Out of two prototypes, one (proto I) will be integrated with 30 mm turret and another

(proto II) with RCWS (Remote Controlled Weapon Station).


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3. SCOPE OF WORK

Sr.No

Specifications / Requirements Remarks byDA

3.1 Manufacturing as per Para 4.1i. Hull envelop and hull system aggregatesii. Mounting blocks / brackets for Automotive and non-

automotive aggregates including add-on armour,power pack, drive line, shock resistance seats, otherequipments, etc. .

iii. Drivers, stick commanders, troopers, Engine &transmission hatches, ballistic louvers for cooling airintake and exhaust

iv. Anti-surge vane including actuating mechanismv. Towing and lifting hooks

vi. Bulkheadsvii. Ballistic louvers for cooling and air intake & exhaust

systemviii. Rear door with rampix. Water Tanksx. Maintenance portsxi. Battery compartmentxii. Miscellaneous items, etc

3.2 Design, Development and Integration as per Para 4.2i. Fuel System

ii. Pneumatic Systemiii. Hydraulic Systemiv. Actuation system for louvers, hatches & rampv. Drivers Stationvi. Stick Commanders stationvii. Commanders & Gunners station(for RCWS version )viii. Winch Systemix. HVAC Systemx. NVH Designxi. Electrical / Electronic System, etc

3.3 Assembly / Integration as per Para 4.3i. Integrated Power Pack (IPP)ii. Under Chassis Driveline (UCD)iii. 30 mm turret (Proto-I)iv. RCWS (Proto-II)v. Hydro-jetsvi. Crew seatsvii. Vision Devicesviii. Composite Armourix. Winch systemx. GPS Systemxi. NBC System


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xii. Electrical and electronic systemsxiii. Combat support equipment like water tanks, firing

ports, fire extinguishers, shovel, Special PurposeTools and Accessories (SPTA), wooden log, pickets,personal combat kits, etc

3.4 Testing as per Para 4.9i. Stage Inspection of systems / sub systems for

- Manufacturing Process- Integration / assembly checks- Functionality and performance

ii. Vehicle testing, trials and acceptance as per ATP

3.5 Documentation

i. Detailed Design report for systems / subsystems

designed by DAii. Process documents for manufactured systems/ sub-

systemsiii. GA, Assy & sub-assy & part drawings for all systems

manufactured/designed & developed by DA as a part ofthis development contract

iv. User, technical and Maintenance Manuals of allsystems & sub-systems sourced / developed by DA

v. Test Certificates for materials / items / componentsvi. Quality check documents pertaining to end of assembly

line tests

3.6 Deliverablesi. One bare hull for blast testing ( without machining)ii. Quantity one prototype fitted with 30 mm turret for

designers trialiii. Quantity one prototype with RCWS for User Assisted

Technical Trials (UATT)iv. Documentation as per para 3.5 above.v. Maintenance Tool kit, SPTA, spares, consumables to

cater for designers and user assisted technical trials.

3.7 Association with trialsDA will associate with Designers and User assisted technicaltrials and will be responsible for in-situ repair, maintenance,minor modifications of systems designed and developed as apart of this work contract. For all manufactured parts, in-situsupport will be provided by DA on case to case basis.

3.8 WarrantyThe DA will provide warranty coverage of one year from thedate of acceptance (not applicable for bare hull) for all the

systems / sub systems manufactured and developed.


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4. SYSTEM DETAILS4.1 Manufacturing

Sr.

No.

Specifications / Requirements Remarks

By DA

4.1.1 The approximate dimensions of the bare hull are asfollows:-

Length : 7900 mm

Width : 2800 mm

Height : 1650 mmPlease ref GA layout enclosed at Annexure AEstimated finished weight of Steel Armoured Hull with steelstructure will be of the order of 3800 to 4000 kg. (Withoutany fitments)

4.1.2 Material of hull structure/space frame - TISCON 500D /Equivalent Steel with standard sections.

4.1.3 Hull envelope-Monocoque constructionPlate thickness(i) 5 mm thick base armour all around,(ii) 5 mm thick plate at inner hull bottom.(iii) 6.5 mm thick plate at outer hull bottom.Material type - Miilux 300 to 500 BHN / equivalent

hardness.

4.1.4 The design of hull will be provided by VRDE. DA willevaluate the design from manufacturability point of viewand suggest suitable changes. Thereafter manufacturingdrawings will be prepared by DA based on correctedinputs.

4.1.5 DA will provide mounting arrangement for add-on armouras per design and scheme from VRDE and will carry outits assembly on the vehicle.

4.1.6 The hull envelope and structure will be welded usingsuitable welding process so that the Heat Affected Zone(HAZ) will not exceed the temperature beyond thespecified limit provided by armour / steel supplier.

4.1.7 The distortion levels - not to exceed 1.5 mm/m.

4.1.8 The hull envelope will be subjected to shot peening /copper slag blasting.


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4.1.9 The hull envelope will be machined (Excluding bare hull)at the places of Engine mounting, transfer case mounting,hatches, ramp, Under Chassis Driveline and the places asgiven in the hull drawings. For prototype 1 machining willbe done for Turret Ring of 30 mm Gun and Rotary Base

Junction location. The base turret ring will be integratedwith hull top plate as per drawing. For prototype 2,machining will be done for RCWS mounting. Theaccuracy of the machining should be as per requirement.Alternatively DA can opt for the procedure as given in4.1.22 below.

4.1.10 Cutting of profiles for openings of rear door, hatches,vision devices and firing ports will be carried out usingplasma / laser cutting or any other advance process.

4.1.11 Standard Engineering practices will be followed formanufacturing of all necessary mountingbrackets/attachment devices of hull. Weight optimizationwill be done at all places and wherever feasible lightweight materials will be used so that weight penalty isreduced.

4.1.12 Maintenance ports are at the bottom of the hull in enginecompartment.

4.1.13

Bulkhead will be provided with appropriate thermalinsulation material for Integrated Power Pack as per NVHstudies by DA.

4.1.14 Profile along with full design of the cover of ballisticlouvers for cooling air intake and exhaust system will beprovided by VRDE in consultation with IPP supplier.

4.1.15 Mounting brackets and maintenance ports on the bulkhead

4.1.16 Skydeskfoot pads will be used for shock attenuation

4.1.17 Ramp actuation system including all hydraulic componentsand seals for rear door will be sourced as per thedimensioning, rating and mounting details provided byVRDE

4.1.18 The hull envelope will be spray painted with Zinc richprimer followed by camouflage painting as per standardprocedure


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4.1.19 The first hull will be manufactured as a bare hull for blasttesting without spray painting and machining. Based outthe outcome of blast testing, there may be requirement tocarry out certain repair works/local modifications in thesame bare hull and subject it to retest for blast. DA will

carry out such changes. The cost of all freight charges forbare hull for blast testing will be borne by VRDE.

4.1.20 The second hull will be manufactured incorporating shapemodifications if any based on blast testing of bare hull andwill be integrated with all automotive and non-automotiveaggregates.

4.1.21 The third hull be manufactured and integrated with allautomotive and non-automotive aggregates based upondesign improvements obtained from designers trials of

second hull prototype.

4.1.22 Suitable manufacturing processes will be evolved by DAand approval for the same to be obtained from VRDE.

4.1.23 The DA will have facility for cold bending of the armourplates. The minimum bending radius should be in therange of 8xt12xt (t= thickness of the plate).

4.1.24 The prototypes are amphibious hence all the openings

need to be sealed for water ingress. The seals will besourced by DA from the vendor identified by VRDE or DAmay also suggest alternate source with approval fromVRDE

4.1.25 Since the hull is for combat applications with amphibiouscapability, there is a need to properly evolve armourwelding procedures including edge preparations, WPS,welder qualifications and weld jointstesting.

4.1.26 Suitable fixtures for handling the jobs will be developed by

DA.

4.1.27 The hull envelope will be tested by DA for water ingress bysubmerging it in static water tank with blinds fitted onopenings. All tests should be conducted in presence ofVRDE Reps


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4.2 Design, Development and Integration

4.2.1Design & development of fuel system

Sr. No. Specifications / Requirements RemarksBy DA

(i) Design and manufacturing of 250 litre (approx.) capacityfuel tanks- qty 02 nos.

(ii) The shape of the fuel tanks will be given by VRDE. DA willmanufacture the fuel tanks as per IS standard.

(iii) Assembly of fuel tanks to the hull envelope

(iv) Provision of the following- Fuel supply line- Line filters- Emergency fuel tank- Fuel gauges, sensors and dip sticks- Armour envelope for fuel tanks- Anti explosion materialused to prevent blast of fuel tanksagainst Small Arms fire.- Source of supply M/s Meera International, Delhi, OR M/sDVM International, Delhi OR M/s TAML, Bangalore

4.2.2 Design & development of Hydraulic systems

Sr.No.

Specifications / Requirements RemarksBy DA

(i) Provision of hydraulic drive for winch system and rear doorramp. The details like location, ratings, speed of operationetc will be provided by VRDE. Also the hydraulic actuatorswill be selected for actuation of IPP hatch, Anti-surge vaneand louver mechanism. Suitable hydraulic system (eitherone or multiple) will be selected for these operations basedon the feasibility study by DA.

(ii) This involves design & development of a hydraulic circuit /accumulator base system for the requirements of varioushydraulic consumers. (Excluding hydraulic system forcooling fans of Integrated Power pack).- Development of necessary interface hoses, controlvalves and other hydraulic aggregates- Circuit diagram and system logic will be provided by

VRDE.


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(iii) Integration of all hydraulic components and reservoirs atsuitable location

(iv) Development of man machine interfaces (Display &controls) for various actuated devices at suitable locations

4.2.3 Design & development of ballistic louvers actuating mechanism andautomatic engine shutdown

Sr.No.


(i) DA will cater for design interface requirement under NBCthreat for cooling air intake and exhaust louvers, actuating

mechanism for engine compartment hatches (hydraulicsystem as mentioned above) with necessary interface forengine shutdown & re-actuation mechanism. The interfacewill be provided through an electronic signal from the autoshutdown interface unit. The display and control units willbe provided at the suitable locations for the same.

4.2.4 Development of Drivers, commanders and gunners stations

Sr.No.


Drivers station(i) The location of Drivers Station will be on the right hand

side of the vehicle adjacent to the IPP

(ii) DA will carry out ergonomic design of vehicle controls likedashboard, steering, brake pedal, accelerator pedal, gearshift lever, parking brake and drive controls like differentiallock, drive selection lever, hydrojets joystick, hydraulic

controls, etc.(iii) Development of Vehicle Dashboard

(iv) Assembly of drivers hatch and vision devices

(v) Assembly of blast resistant seat

Stick Commanders station

(i) The commanders station is locatedjust behind the driversstation


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(ii) Assembly of hatch and vision devices

(iii) Assembly of blast resistant seat

Commander & Gunners stations-

This is only for proto II which is mounted with RCWS. For 30mm turretversion (proto I), the commander & gunners stations will be integralpart of turret.

(i) The commander & gunners station will be at center of thevehicle.

(ii) Assembly of hatches, blast resistant seats, vision devicesand RCWS control consoles and display

(iii) Integration of RCWS (ProtoII)

(iv) Integration of 30 mm turret system for Proto-I. DA willcarry out mechanical fitment of RBJ, harness preparationon stator side & turret integration on vehicle and associatein functional testing.

4.2.5 Development of Troopers compartment

Sr.

No.

Specifications / Requirements Remarks

By DA

(i) The troopers compartment will be at the rear of thevehicle

(ii) Mounting / integration of blast resistant seats

(iii) Assembly of firing ports

(iv) Mounting of periscopes / vision devices

(v) Assembly of escape hatches

(vi) Assembly of water tanks, stowage boxes and other combatloads

(vii) Assembly of hydraulically actuated rear door ramp

(viii) Assembly of skydesk pads at appropriate locations


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4.2.6 Design for NVH, HVAC and NBC system. Development of HVAC & NBCsystems

Sr.

No.Specifications / Requirements Remarks

By DA

HVAC system

(i) DA will be responsible for design and development ofHVAC system for the prototypes

(ii) The operating temperatures will be -20 Cto +55C

(iii) Minimum temperature drop 10 C with pull down time of20 min in Static vehicle condition.

(iv) Suitable heating arrangement to be provided for lowtemperature environment.

(v) Development of ducting and ports

(vi) Interfacing of HVAC control unit at drivers station

(vii) Insulation lining to be provided with a suitable thickness toachieve required cooling effectiveness. The materialshould be such that minimum thickness (of the order of 10mm or less) is achieved.

NVH Design

(i) DA will carry out NVH studies of vehicle based on whichDA will suggest and implement necessary measures. DAwill also provide design and development of enginebulkheads, localized noise insulation for enginecompartment.

NBC system

(i) NBC system will be installed in proto-II

(iii) Louvers & engine shutdown mechanism with its integrationand Interlock harness will be developed by DA to the logicprovided by VRDE.

(iv) BC filtration system without harnesses will be provided byVRDE. Harnesses will be developed by DA.

(v) DA will develop interface unit for Auto-shutdown forvarious units under NBC threat. For this, VRDE will providenecessary specifications of various interfaces. Also

harness from this unit to various control elements will bedeveloped by DA.


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4.2.7 Design & development of electrical / electronic system

Sr.No.


(i) DA will prepare a detailed design on Vetronics systemsbased on circuit diagrams prepared by VRDE. DA willprocure/develop the subsystem/items as per the listprovided by VRDE. Additional/extra subsystem / itemsrequired to ensure overall system functionality, will also beprocured/developed by DA. Integration of all equipment,systems, subsystems, development of heat shrinkablecable harnesses with MIL 38999 series II connectors,harness layout & integration / interface with systems willbe carried out by DA.- The electrical system will comply with MIL 1275D- The MOTS (Military Off The Shelf) equipments shouldcomply with JSS 55555 and MIL 461F

(ii) Integration of FIM equipments, systems, subsystems,preparation of cable harnesses with connectors (whereever required), harness layout & integration / interface withother systems will be carried out by DA.

(iii) The harnesses developed by DA shall be MIL qualified. Allcomponents, devices shall be of MOTS (Military Off The

Shelf) items.

(iv) Provision of limit switches for all hatches and interlockingthem with NBC auto shutdown mechanism and provisionof signal at RBJ for fire inhibit.

(v) Provision of Battery, battery isolator switch & batterycontactor by DA (qty per prototype given below)-HBL make BR 140- 12 VDC/160AH02 nos-Battery isolator switch 01 no & Starter contactor 01

no

(vi) Alternator - FIM by VRDE, 10kW / 28V DC withoutharness.

(ix) Power Distribution Box (PDB) Development by DA.Tease-free, trip-free, push/pull on/off thermal circuitbreakers of proper current rating as fuses should be used .PDB should have enough spare power taps.

(x) Harness layout plan in 3D modelwill be prepared by DAin consultation with VRDE.


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(xi) Cable Harnesses - The electrical cable harnesses will bedeveloped and assembled on the vehicle by DA as perVRDE approved plan. Cable harness manufacturing tocomply with - STD JSS 6145-04

(xii) Engine Starting System - Starter motor will be FIM byVRDE. Starting system components along with harnesswill be provided by DA. Provision for slave starting will bemade by DA.

(xiii) Power pack Electronics & Electrical sensors will beprovided by VRDE, DA will carry out interfacing of thosesensors & inputs/outputs with dashboard with appropriateharnessing.

(xiv) Vehicle Dashboard - Dashboard design specifications willbe prepared by VRDE. Detailed design and developmentof dash board will be done by DA .- The dashboard will be ruggedized industrial grade unit.- Functional and compliance testing of dash board will beresponsibility of DA.

(xv) Lighting system Military Off- the -shelf items to besourced by DA after approval from VRDE.

(xvi) DA will provide the following:-

- Lighting Control Panel (LCP) & Light Control Box (LCB)- Main Headlight- Headlights with blackout doors- LED dome lights- LED Marker lights- LED reversing light- Fog lights- Inspections lamps with sockets- Reflex reflectors- Horn

(xvii) Periscope Vision System - FIM by VRDE, DA will carry outintegration & mechanical fitment.

(xviii) GPS Navigation System - FIM by VRDE, DA will carry outintegration & mechanical fitment.

(xix) RCWS will be FIM , DA will carry out assembly &integration of RCWS and commander & gunners station(For protoII).30mm turret will be FIM. DA will carry out assembly of30mm turret and RBJ (For protoI).


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(iii) Integration of independent double wishbone suspensionfor front two axles

(iv) Integration of trailing arm suspension system to the reartwo axles

(v) Integration of steering system consisting of steering pump,steering column and steering linkages etc.

(vi) Provision of hydraulic lines from steering pump to steeringgear box and return line.

(vii) Interface of pneumatic line between compressor and airtanks. Integration of pneumatic lines from air tanks towheel ends.

(viii) Integration of drive engagement / dis engagement lever /pneumatic actuators / push button for selection of High-Low and for 8x8 / 8x6 / 8x4 and amphibious driveengagement. Interfacing of differential lock and mountingof its lever in drivers station.Appropriate display for the above shall be included indriver console.

(ix) Integration of ABS, CTIS controls / display at Driversstation

(x) Integration of Gear shift lever of automatic transmission atsuitable location in drivers station. Interfacing of parkingbrake system and mounting of lever at drivers station

(xi) Integration of bump / rebound stoppers on all wheelstations.

(xii) Integration of Brake system on the vehicle with necessarymounting brackets.

(xiii) Assembly of Wheels(xiv) Assembly of CTIS and ABS air tanks in the hull

4.3.3 HydrojetsHydrojets will be connected with mechanical drive system from last axle

(i) Integration of Amphibious drive transmission consisting ofsplitter gear box (01 No), Angle gear box (02 nos) anddriveshaft assemblies on the vehicle hull

(ii) Qty 2 Nos. hydro-jets will be integrated at the rear of thevehicle


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(iii) DA will make provision of proper sealing for all openingsso as to meet the amphibian capability

(iv) Integration of hydro-jet control joystick and control panel atdrivers station

(v) Assembly of Anti-surge vane with actuating mechanism foroperation by driver

(vi) Integration of electrically (03 Nos) & mechanically (01 No)operated bilge pumps at suitable locations inside the hull

(vii) Interfacing of electrical harness from electrically operatedbilge pumps with control console at Drivers station

4.3.4 Winch systemHydraulically actuated winch to be mounted on front side of the vehicle for self-

recovery

(i) The capacity of the winch will be around 10 ton

(ii) Interfacing of hydraulic lines for actuation of winch systemfrom IPP hydraulic circuit / a separate hydraulic source

(iii) Interfacing of winch controls at drivers station

(iv) Provision of Armour protection hood for protection of winch

4.3.5 Integrated Vehicle Electronics Architecture (IVEA)

(i) Required for prototypeII. It will be FIM by VRDE

(ii) DA will provide requisite inputs (Interface ControlDocument) on sub systems which are developed /procured by DA. DA will carry out Mechanical integration

of IVEA & associate in functional testing.

4.3.6 Auxiliary Power Unit (APU)

(i) Required for prototype -II

(ii) Mechanical integration & power cable harness to bedeveloped by DA.


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4.3.7 Integrated Fire Detection & Suppression System (IFDSS)

(i) Required for prototype -II

(ii) Complete IFDSS system with harnesses will be providedby VRDE.

(iii) DA will execute assembly and integration of IFDSS.

4.3.8 Integrated Crew Vision System (ICVS)

(i) Required for prototypeII

(ii) Complete ICVS system with harnesses will be provided by

VRDE. DA will carry out integration of ICVS

4.3.9 Drivers day and night vision system

(ii) Drivers Day & Night Vision system with harnesses will beprovided by VRDE. DA will carry out its integration.

4.3.10 Assembly of other systems

DA will carry out assembly of all the other systems mentioned in the scopeof work. Detail assembly plan will be prepared by DA which will be reviewedand approved by VRDE.


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4.4 List of Items to be Procured / Developed by DA

Sr. No. Nomenclature Qty RemarksBy DA

4.4.1 Steel Armour of 5 mm and 6.5 mmthickness for manufacturing for qty 03hulls

As required,Material -Miilux of400450BHN/equivalent

4.4.2 Structural Steel for manufacturing of 03hulls & Assembly / Sub-assemblyintegration for 02 Prototypes

As required,TISCON500D/equivalent

4.4.3 Stiffener plates (1015 mm thick) As required

Welding consumable & Fasteners. As required

4.4.4 Anti-explosion material -To be quotedas optional

As required

4.4.5 Materials for fabrication/manufactureand assembly of mounting brackets andmiscellaneous items mentioned in thescope

Lot

4.4.6 Shock Attenuation foot pads (skydesk)- To be quoted as optional

As required,Make - M/s MKU,Kanpur

4.4.7 -Blast resistant Seats for driver, stickcommander & Crew (08 nos)-Commander & gunner (for RCWSversion only)- Entire seat package to be quoted asoptional

2 Sets

1 Set,Make - Jankel ,UK

4.4.8 Dash Boarddesign and developmentincluding sensor interfaces and frontpanel displays as per scope

2 Nos

4.4.9 Fuel system aggregates 2 Sets

4.4.10 Hydraulic System aggregates 2 Sets

4.4.11 Pump Interfacing unit for hydraulicsystem for winch, anti-surge vane andramp

2 Sets

4.4.12 Aggregates of drivers , commander,troopers station as per scope

2 Sets

4.4.13 Bulkheads for thermal and noiseisolation for engine compartment and

NVH aggregates for engine and otherparts based on NVH study

2 Sets


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4.4.14 Ballistic louvers, hatches, rear doorramp with actuator as per VRDEspecifications

2 Sets

4.4.15 Brake & accelerator pedals 2 Sets

4.4.16 Mounting accessories for Hydrojetsystem

2 Sets

4.4.17 Winch System (10 ton capacity,hydraulically operated)

2 Nos

4.4.18 Design and development of HVACSystem

2 Nos

4.4.19 Manufacturing of various brackets andother utilities as per scope

lot

4.4.20 Realisation of subsystem to hullinterfaces on caseto case basis as per para no 4.3.1 (i)

At actuals

4.4.21 Engine starting system excludingstarter motor

2 Sets

4.4.22 Harness integration for ICVS (proto II) 1 No

4.4.23 Power distribution box (PDB) 2 Nos

4.4.24 Heat shrinkable cable harnesses withMIL 38999 Series II connectors

2 Sets

4.4.25 Lighting control panel & light controlbox (LCB)

2 Sets

4.4.26 Main Head light 2 Sets

4.4.27 Head light with Blackout door 2 Sets

4.4.28 LED Dome light 20 Nos.

4.4.29 LED Marker light 14 Nos.

4.4.30 LED Reversing light 4 Nos.

4.4.31 Fog light 4 Nos

4.4.32 Inspection lamp assy with sockets 12 Nos.

4.4.33 Horn 2 Nos


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4.5 List of Free Issue Material (FIM) by VRDE

Sr. No. Nomenclature Qty RemarksBy DA

4.5.1 Integrated Power Pack (as mounted onsub frame) consisting of Engine,Transmission, Air Intake, exhaust andRemote liquid Cooling System withaccessories

2 Sets

4.5.2 Under Chassis Drive line consisting ofAxles with independent Suspension,Transfer Case, Differentials, propellerand drive shafts, steering system, brakesystem with ABS, Wheels, Tyres withRun Flat Inserts, CTIS system, andAmphibious drive system

2 Sets

4.5.3 Hydrojets with controls and accessories 4 Nos.(2 sets)

4.5.4 Add-on / composite Armour for twoprototypes

Asrequired

4.5.5 Vision Systems for Driver, Commander,stick Commander, Gunner & Crew

compartment

2 sets

4.5.6 Remotely Controlled Weapon Station(RCWS) for proto II

1 no.

4.5.7 30 mm turret system with RBJ for protoI

1 no.

4.5.8 Biological and Chemical (BC) filtrationsystem

1 Set

4.5.9 Alternator and starter motor (part ofIPP)

2 nos.

4.5.10 Power pack E & E System includingsensors

2 sets

4.5.11 GPS Navigation System 2 Nos.

4.5.12 NBC instrumentation (Proto II) 1 Set

4.5.13 Drivers Day & Night vision system(Proto II)

1 No.


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4.5.14 Integrated Crew Vision System ICVS(Proto II)

1 set -

4.5.15 Integrated Fire Detection & SuppressionSystem (IFDSS)- (Proto II)

1 set -

4.5.16 Auxiliary Power Unit (Proto II) 1 No. -

4.5.17 Integrated Vehicle ElectronicsArchitecture(IVEA)- (Proto II)

1 No. -

4.5.18 Turret ring for hull for 30 mm (Proto I) 2 No


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4.6 Timelines

Sr. No. Activity Duration(months)

Total(Durat

ion)

RemarksBy DA

4.6.1 Placement of Development Contract D 0

4.6.2 Design Finalisation for First Bare Hull D1= D + 2 2

4.6.3 Manufacture of First Bare Hull (addtwo months)

D2 = D1+ 2 5

4.6.4 Design Finalisation of Second Hull D3 = D2 + 2 7

4.6.5 Manufacturing of Second Hull D4= D3 + 3 10

4.6.6 Testing of Second Hull D5= D4 + 1 11

4.6.7 Integration of Automotive Aggregates D6= D5 + 2 13

4.6.8 Integration of Non-AutomotiveAggregates

D7= D6 + 1 14

4.6.9 ATP of First WHAP prototype D8= D7 + 1 15

4.6.10 Designers trials at VRDE D9= D8 + 2 17

4.6.11 Design updating if any for Third Hull D10= D9 + 1 18

4.6.12 Manufacturing of Third Hull D11= D10 + 3 21

4.6.13 Testing of Third Hull D12= D11 + 1 22

4.6.14 Integration of Automotive Aggregates D13= D12 + 1 23

4.6.15 Integration of Non-AutomotiveAggregates

D14= D13 + 1 24

4.6.16 ATP of Second WHAP prototype D15= D14 + 1 25

4.7Proposed Payment Terms & Conditions

Sr. No. Proposed Payment Terms & Conditions RemarksBy DA

4.7.1 30% of total order value be paid on submission of Design forManufacturability Report within 3 months from the date ofplacement of supply order against submission of BankGuarantee


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4.7.2 30% of the total order value will be paid on completion ofinspection, acceptance and delivery of First prototype.

4.7.3 30% of total order value plus 100%taxes & duties will be paidafter inspection, acceptance and delivery of Second prototype.

4.7.4 Balance 10% of total order value covering warranty period willbe paid on expiry of warranty period of second prototype OR onsubmission of BG, covering warranty period

4.7.5 Advance payment will be made against proper bank guaranteefrom Nationalized bank for 110% of the advance claimed.

4.7.6 If the contract is terminated due to default of the Contractor, theadvanced amount would be deemed as interest bearingadvance at a prevailing bank rate which will be compoundedquarterly and will be recovered from the Contractor.

4.7.7 The vendors should quote as per the specimen / templateenclosed at Para 4.10

4.7.8 FIM Will be issued by VRDE as and when required in astaggered manner. The total cost of the FIM is Rs 450 lakhs(approx.) for which the contractor will have to provide BankGuarantee to equal cost of the store, valid till stores are in theirpossession, to safeguard the Govt interest.

4.7.9 F.O.RVRDE, Ahmednagar

4.8 General Points

Sr. No. Specifications / Requirements RemarksBy DA

4.8.1 Operating environment : Following are the specifications for operation of WHAP

(i) Operating temperature : -20C to +55C

(ii) Storage Temperature : -40C to +70C

(iii) Altitude : Up to 4000 m above sea level

(iv) Humidity : 5-95% RH

(v) Vibration (Veh mounted equipments) : 1.5 g pk-pk, 8500 Hzlevels

(vi) Shock (Veh mounted equipments) : Half sine shock pulse, 11ms duration, 15 g peak

4.8.2 Miscellaneous items


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DA will provide tool kit with each prototype consisting of itemslike Lifting jacks, fuses, spanner kit, essential spares of electricalsystem, gauges, etc

4.8.3 Workmanship

(i) The workmanship should be in accordance with the acceptedengineering and production standards of the industry so as toensure operation of the prototypes under severe combatenvironment.

(ii) Metal having pitted or corroded surfaces are not acceptable.Shearing and chipping should be done neatly and accurately. Allsharp edges and burrs should be removed. Burred surfaces andflame cut materials should be ground smooth.

(iii) Welding should be done neatly and effectively executed andshould be free from all flaws and defects. Welding should betested OK for porosity and cracks. Relevant welding tests to becarried out by DA.

(iv) Bolt-holes should be accurately drilled and burrs should beremoved. Washers and lock washers should be provided onbolts, studs and cap screws having straight threads. All bolts,nuts and screws should be correctly torqued. All bolts shouldhave positive locking i.e. either Nylon lock nuts or spring washerswith plain nuts should be used.

(v) All the steel parts will be zinc plated or hot dip galvanized as perIS-2629.

(vi) All Aluminum parts will be hard anodized.

(vii) Each part should be carefully chosen with due consideration toits weight since the vehicle is amphibious and the overall weightof the vehicle should be within stipulated limits. System wiseweight budget will be given to DA which will have to be compliedwith. Any deviations to this to be approved from VRDE. Detail

weight estimates of all aggregates will be forwarded to DA byVRDE within fifteen days from the DoM review meeting betweenVRDE and DA. Tolerance on steel thickness of +/- 10 % will beconsidered while estimating the weights.


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(viii) VRDE reserves the right to incorporate changes/deviations ofminor nature to the specifications and drawings in order toenable the prototypes to meet overall objectives. DA maysuggest any deviation / improvement in the specifications anddrawings which may be necessary during the development

process. In the event of technical issues arising during theexecution of said work contract, joint meeting betweenrepresentatives of VRDE and DA will be convened to discussthe matter and arrive at an appropriate solution. Necessarytechnical waiver will be granted by the said committee on case tocase basis and the work will be processed as per the decisionstaken by the committee. DA will be bound by Committeesdecision. The committee will also be empowered to review theprogress of the work by conduct of review meetings, stageinspections, take necessary course corrective actions to meetthe project objectives.

(ix) DA will start manufacturing of hull and development of systems /sub-systems after obtaining approval from VRDE. For systems,which involves design and development, system wise designreviews will be conducted and necessary approvals will becommunicated to DA by VRDE.

(x) All drawings, detailed circuit diagrams, data sheets of COTS andMOTS used items, sources, detailed document on softwaredeveloped for embedded hardware with details on IDE platformshall be submitted after completion of task

(xi) (1) The IPR in respect of overall concept and configuration ofWHAP and its variants in the areas of survivability, protectionand amphibious design will be with VRDE.

(2) IPR for manufacturing, tooling, jigs and fixtures, assemblyprocedures will rest with DA.

(3) Foreground IPR in respect of all new technologies / systems /subsystems / processes pertaining to this contract, inclusive ofmutually finalized overall hull envelope of WHAP and its variants

but excluding 1 and 2 above, will be held jointly by VRDE andDA.

4.9 Testing : Broad Level Acceptance Test Plan (ATP)

Following paragraphs lay down the guidelines for testing and acceptance of

manufacturing of hull system and integration automotive / non-automotive

aggregates of WHAP. System wise detail ATPs will be evolved and tests will be

conducted accordingly. VRDE team will carry out the stage inspections duringexecution of task. VRDE team will be detailed to carry out the final inspection of the


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vehicle before it is cleared for trials. Certificate obtained from supplier/OEM, test

report for items / materials / equipments developed by DA to be submitted to VRDE.

Any corrective measures will be responsibility of DA.

The schedule of ATP to be carried out as given below:

Part I : ATP of Bare Hull after 4 months of placement of contract

Part II : ATP of First Prototype after 13 months of placement of contract

Part III :ATP of Second Prototype after 23 months of placement of

contract

4.9.1 Part I : ATP of Bare Hull4.9.1.1 Visual and mechanical Inspection:

The first bare hull will be examined for the following: -

a) Dimensions

b) Distortion checks

c) All Welded joints with DPT and any critical joints / area of hull with

radiography

d) Inspection of fasteners and its mountings

e) Various openings

f) Mounting points for dummy loading

g) Dummy loading

h) Fixture / test set up

i) Attachment of lifting points

4.9.1.2Blast Simulation : After the visual and mechanical inspection, the bare

hull along with simulated test set up will be moved for blast simulation at one of

the DRDO Establishment. The DA will assist in carrying out of blast simulation test

in terms of installation of test set up, engineering support, etc on need basis.

4.9.2 Part II: ATP of First Prototype

The qualified prototype will be examined for the following:-

a) General appearance


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b) Dimensional checking

c) Distortion checks

d) Finishing at various openings

e) Welded joints with DPT and any critical joints / area of hull with

radiography

f) Inspection of fasteners and its mountings

g) Integration of Automotive Aggregates

h) Integration of Non-automotive Aggregates

i) Provision of lifting and towing hooks

j) Ease of hatches / ramp operation and locking arrangements

k) Sealing of hull at all the openings

l) Camouflage painting

m) Fixing arrangement for composite armour

n) Testing of electrical and electronic systems

i) Dimensional Testing :- The hull system will be subjected to

dimensional checks as per the manufacturing drawings. Any deviations found

will be rectified by the DA.

ii) Finishing at various openings:-All the surface finish and profile of

cut for the openings will be checked as per manufacturing drawings. Any

deviations found will be rectified by the DA.

iii) Testing of Welded Joints:- The armoured hull will be tested to

determine following weld defects, if any (visual).

a) Blow Holes

b) Cracks

c) Incomplete welding (left out welding)

d) Running of welding

e) All weldments will be subjected to DPT and any critical joints /

area of hull with radiography

iv) Metallographic Examination:- The samples selected at various

locations of the wall will be subjected to macroscopic examination to

find out the following defects;


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a) Lack of fusion

b) Joint offset

c) Incomplete penetration / fusion of root

d) Lack of side wall fusion

v) Longitudinal bend test:- The welded specimen will be subjected to

longitudinal bend test as per test standard ASME section ix, to find out

the root bend.

vi) Transverse tensile test:- The welded specimen will be subjected to

transverse bend test as per test standard ASME sec ix, to find out UTS

of the weld.

vii) Leak Proof Testing:- The armoured hull with payload fitted with all

sealing with all openings will be subjected to leak proof testing, where

the hull needs to be immersed in water. There should not be any traces

of water inside the hull.

viii) Integration Analysis:- All the automotive and non-automotiveaggregates integrated in the vehicle will be measured as per assembly

drawings provided by VRDE. Any deviation found needs to be rectifiedby DA.

ix) Testing of Electrical and Electronic systems:- Functional testing ofcomplete Vetronics system for prototype I & prototype II will be carriedout as per ATP. ATP document will be prepared by VRDE to carry outacceptance tests.

x) Detailed ATP for Hull will be prepared by VRDE and forwarded to DAbefore assembly of automotive and non-automotive system

4.9.2.1 Representative details of some of the tests mentioned are given below:-

Dimensional Checks

Sr.No.

Parameter

1 Overall length

2 Overall width

3 Overall height

4 Distance from 1st

Axle to 2nd

Axle


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5 Distance from 2ndAxle to 3rdAxle

6 Distance from 3rdAxle to 4th Axle

7 Angle of approach

8 Angle of departure

9 Minimum ground clearance

10 Front Vehicle overhang

11 Rear vehicle overhang

12 Front track width

13 Rear track width

14 Ramp angle

15 Wheel geometry

Weighment (Unladen)

Sr.No.

Parameter

1 Front two Axles

2 Rear two Axles

3 GVW of vehicle (kg)

Ignition Box/Steering Lock

1 Ignition key operation in 04 position

2 ON/OFF, Lock/Unlock

HVAC in Vehicle

1 Functioning of HVAC

Horn

1 Functioning of Horn and Stop switch

Power Steering wheel1 Position

2 Function of steering lock

Vehicle Dashboard

1 Lower air pressure indicator and bipper

2 High beam indicator

3 Parking brake indicator

4 Gauges


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5 Speedometer with odometer

6 Coolant temperature gauge

7 Low oil pressure indicator

8 Interlock test

9 ABS indicator & switch

10 Glow plug Bipper

11 CTIS indicator & Switch

12 Combination switch

13 Light indicator

14 Reverse gear indicator and Buzzer

Functional test of lighting system

1 Head lamps

2 Side indicator (Front & Rear)

3 Parking light

4 Tail lamp Reverse and Brake light

5 Dome lights & inspection lamps

6 Fog lamps

Accelerator pedal1 Free movement of pedal

Brake pedal

1 Free play (15-20 mm)

2 Free movement of pedal

Parking brake

1 Engaging and releasing of brake

Fitment/function of Misc. accessories

1 Footsteps bracket

2 Function & alignment of door lock/Hatch/Glove box

4.9.2.2 Designers trials:-

The prototype 1 with payload will be subjected to track trials at VRDE. The


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designerstrials will be carried out at NCAT as per VRDE test code followed

for evaluation of Army vehicles. The tracks and instrumentation for the same

will be provided by VRDE. Following are some of the tests (list not

exhaustive) to be conducted during the trials. Detail trial plan will be evolved

at a later stage.

(a) High speed track

(b) Cross Country track

(c) Pave track

(d) Steering Pad

(e) Corrugated track

(g) Loading & weighment

(h) Speedometer / Odometer calibration

(j) Max. Speed

(k) Acceleration

(l) Gradeability & parking brake effectiveness

(m) Fuel consumption

(n) Noise level

(o) Step climbing

DA will be associated with the trials of the prototypes. FOL for the trials including

cost of tracks and instrumentation system will be borne by VRDE.

4.9.2.3 Floatation Trials:-Floatation trials of the first prototype-I will be carried outby VRDE, DA will associate in the trials for in-situ repairs.

4.9.2.4 Dynamic checks :-

These are representative trials. Detail trial plan will be evolved at appropriate time.

1 Steering position

2 Steering effort/movement/wobbling

3 Steering operation on both sides

4. Steering wheel self-centering

5 ISO tests for transient stability and handling maneuvers

4.9.2.5Leakage checks:- Leakage checks to be carried out for fuel, oil, air andcoolant of the concerned systems / sub-systems.


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Date post:	04-Jun-2018
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Specifications of Whap Hull

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