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TECHNICAL SPECIFICATIONS FOR INTEGRATED ROBOTIC THERMAL SPRAY COATING FACILITY

SCOPE: Manufacture, supply, erection / installation, commissioning, part proving, training on operation and maintenance of the complete Robotic thermal spray coating facility. PURPOSE : Plasma coating, Flame coating and HVOF coating of Aero engine parts using Robotic coating system.

Integrated Robotic Thermal Spray Coating Facility consisting of following:

(I) Plasma Coating Equipment complete with

• Plasma Control Unit

• Process Gas Controller

• Ignition and Measuring Unit

• Power Supply Unit

• Powder Feeder Unit

• Gun Cooling Water Chilling Unit

• Plasma Spray Gun

(II) Gas Fuel HVOF Coating Equipment consisting of (DESIRABLE) – Itemized cost of the item to be given

• HVOF Spray Gun

• Process Control Unit

• Powder Feeder Unit

(III) Powder Flame Spray Coating Equipment consisting of (DESIRABLE) – Itemized cost of the item to be given

• Powder Flame Spray Gun

• Gas Flow Meter

• Powder Feeder Unit

(IV) Fully Integrated Part & Gun Manipulation System complete with

• 6 Axis Thermal Spray Robot

• Tilting Turn Table driven by 2 external robot axis

• Servo track for Robot

(V) Auxiliary Systems complete with

• High Performance Scrubber Unit (Wet scrubber desirable in place of dry scrubber. To be quoted separately for dry / wet scrubber))

• Sound proof Booth

• Electrical Distribution Unit

(VI) On- line Thermal Spray Monitoring Unit (DESIARBLE) - Itemized cost of the item to be given

(I) Specifications of Plasma Coating Equipment and System Components:

• Modular System

• Mass Flow Control for Process gases

• Gas and Electrical components strictly separated

• Fully conformant with all present safety regulations

• Easy Service and maintenance

• Operation capability at high temperatures (up to 40 Deg C)

• Easy Operation by operator interface

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• Computerized process operation

• Capable to handle all current plasma spray guns & Internal guns

• Capable to operate gravimetric / volumetric powder hoppers

(a) Plasma Control Unit : • Modular Design

• Operator friendly control system by screen page with quick menu access.

• Contain Electrical /Electronic components only

• PLC for process control & all safety interconnections including Gas leak detectors

• Real time process control

• High performance industrial PLC

• Closed loop spray parameters ‘Touch Screen’ control

• Storage and recall capability (min. 100 spray recipes) on PCMCIA

• Process data and error message display

• Diagnostic system with display for fault finding

• Automatic gun ignition start up sequence

• Closed Loop Power control capability (current or secondary gas control)

• Monitoring & protection of Plasma gun in operation by selecting the model on a data base.

• Printing capability including printer permitting reporting of actually used parameters, consign values, status history for maintenance purpose, report data.

• Full integration capability with Part & Gun handling system.

• Electrical Specifications : 1 Phase, 230 V, 50Hz

(b) Process Gas Controller : • Modular Design & CE conforming.

• Contains gas and cooling air controls only

• Three Plasma gas lines Argon, Nitrogen and Hydrogen controlled by closed loop mass flow regulators. Argon 3- 100 NLPM, Hydrogen 0.4-20NLPM, Nitrogen 3-100NLPM

• Gas mass flow controller with ±2% accuracy

• Carrier gas lines supply Argon / Nitrogen

• Air Pressure regulation for the plasma gun substrate cooling air jets.

• Built-in Hydrogen Gas Leak Detector

• Comply with all present safety regulations

(c) Ignition and Measuring Unit: • Measuring of cooling water data close to spray gun

• Measuring of electrical data close to spray gun

• Electronic ignition system (electromagnetic compatibility)

• Water conductivity sensor

• Control of plasma gas pressure before the plasma spray gun

• Additional flow switch to ensure minimal cooling water quantity for the spray gun.

(d) Power Supply Unit :

• Thyristor controlled unit & CE conforming.

• Output : 100 V DC: up to 1000 A DC

• Efficiency : >90%

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• Reactive Power : 0.8 approx

• Drive : by digital data bus

• Maintain the current supply to the gun constant regardless of any voltage fluctuations (±10%) or changes in the electrical arc resistance.

• LED error display enabling easy localization of malfunctions & transformers.

• Built-in “Soft-start” feature for plasma operation.

• Electrical Specifications : 3 Phase, 415 V , 50Hz

(e) Powder Feeder Unit :

• Volumetric type (Disk) & CE conforming.

• Two Powder hoppers

• Hopper Capacity 1 to 1.5 Liters per hopper

• Built-in Stirrers.

• Particle size capability : 2 to 200 microns

• Maximum feed rate : up to 10 kg/hr

• Accuracy : ±1%

• Carrier Gas : Nitrogen or Argon

• Equipped with hardware to handle Metallic and Ceramic type powders.

• Hoppers to have Powder heating arrangement (optional)

• Drive: By digital data bus.

• Electrical Specifications : 1 Phase, 230V, 50Hz

(f) Gun Cooling Water Chilling Unit :

• Thermal capacity 30 KW (Approx)

• Closed Loop operation

• CE conforming

• Suitable for Ambient temperature of + 10 C to + 40 C

• All components such as cooling water vessel, pumps, piping & connection fittings made of stainless steel.

• Refrigerant : R134 A CFC free

• Gun cooling water circuit separated

• Automatic control of water temperature, pressure and flow

• Automatic gun cooling water treatment (purity and mineral content)

• Gun water inlet pressure max 15 bar (adjustable)

• Gun water flow 17 lit/min at 15 bar

• Cooling Air circulation : 10000m3/hr

• Common chiller unit for Plasma & HVOF systems

• Designed for easy servicing and accommodate all plasma spray guns

(g) Plasma Spray Gun : Both external and internal gun to be provide with the equipment

External gun

• Power rating: Optimum performance at 55KW (100% duty cycle).

• Module : Gun to be Machine Mount type with suitable robot mount

• Plasma Gas temperatures up to 16000° C

• High Plasma Gas velocity in excess of 3000 m/sec

• High Particle velocities up to 600 m/sec • Tungsten tipped Electrode & Tungsten Lined Nozzle for long hard ware life

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• Capability to spray wide range of materials with the same Nozzle & Electrode configuration.

• Powder feed to be external & at the tip of the nozzle.

• Suitable Powder Injectors, injector holders, Air Jets for work piece cooling, hoses, cables, Electrode centering tool, Powder injector distance gauge to be supplied with the gun.

• Plasma spray guns with 6mm nozzle & 8mm nozzle to be supplied separately.

Internal gun

• It is required for thermal spray coating of internal diameter

• Modular and rigid in design

• Plasma power rating up to 16kw

• Quick exchange plasma gun head

• Suitable for plasma spray on internal diameter up to 60 mm

• Length of the gun 700mm (approx)

• Spray head version :90°

(II) Specifications of Gas Fuel HVOF Coating Equipment and System Components (Desirable)

(a) HVOF SPRAY GUN :

• WATER Cooled Hybrid Hardware Oxy-Hydrogen Gas Fuel gun

• Machine Mount version with suitable robot mount.

• Axial Powder Feeding mechanism.

• Using optionally available gun hardware, it should be possible to convert the gun for use with different fuel gases viz Natural Gas, Propane etc.

• Optional hardware for conversion from water cooled to air cooled to air cooled gun.

• Gas Velocity : 2000 m/sec (Approx)

• Combustion Pressure : 600 bar minimum

(b) Process Control Unit :

• Microprocessor controlled unit providing automatic operation of the HVOF system

• Unit designed to light, run & shut off the gun flame

• Unit designed to start, control & stop coating feed material

• Unit to reduce flame to idle to conserve gas & powder

• Monitor the flame, shut the system off and sound an alarm if flame out occurs or the gun should fail to ignite.

• Unit to continuously monitor present fuel, oxygen and air pressures and shut off the system if these supplies are interrupted.

• Unit to provide self diagnostic fault messages and audible alarms.

• Fail safe controls and interlocks to prevent accidental start up or damage.

• Physical separation of electrical components from gas handing components.

• Automatic compressed air purge of electrical compartment and constant ventilation of gas compartment.

• Built-in door interlock safety switch

• Unit to have System status monitor, Test mode, Multi System operation features.

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(c) Powder Feeder Unit :

• Self contained computerized & closed loop feed rate monitoring

• A microprocessor based weight loss metering system to provide continuous closed loop adjustment of material feed rate.

• Powder feed rates to be programmed in grams/min or Lbs/hour.

• Operator to enter the desired feed rate through a key pad & the feeder unit then should automatically establish and maintain desired feed rate.

• Capable of feeding full range of HVOF powders regardless of morphology.

• Accurate powder delivery within ± 1.5 g/min

• Built-in computer control to compensate for normal fluctuations in conditions, such as changes in carrier gas flow, change in powder level, pick up shaft wear etc.

• High pressure hopper assembly of minimum 6 bar pressure & 3 Liter capacity

• Built-in vibrator unit

• Unit to display system operation status & alarm conditions.

(III) Specifications of Powder Flame Spray Coating Equipment and System Components (Desirable):

(a) Powder Flame Spray gun : • Used with either Acetylene or Hydrogen as the fuel gas

• A siphon plug system to mix fuel & oxygen gases in precise volumetric proportions at the gun to provide consistent operation and prevent the possibility of back fire.

• Handheld gun with suitable Robot mount

• Choice of air caps to optimize cooling during spray operation.

• Gun designed for spraying in any position, even upside down with consistent results.

• Simple powder feed and vibrator star / stop via powder feed trigger on the gun.

• A separate Powder On/Off switch box for operating the gun from outside the acoustic room.

• Suitable Air Jet Assembly unit to be supplied with the gun.

• Extension modules (1 foot length) to be offered optionally. (b) Gas Flowmeter :

• Provide precision metering of process gas flow for consistent results

• Regulate and measuring flow of both Oxygen & Fuel gas in manual powder / wire flame spray system.

• Choice of Acetylene & Hydrogen as fuel gas to accommodate* different applications and production needs.

• Built-in safety features such as Check valves & plastic shields.

• Easy to read flow units in both SCFH & NLPM (C) Powder Feeder Unit: • Designed for use with both manual & semi-automated systems.

• Feed Rates – 5 to 300 gms/minute (approx)

• Large 5 Liter capacity production hopper with vibrator mechanism

• Precision carrier gas control using rotameter with separate flow tubes for SCFH or NLPM readings.

• Powder Feed Rate Meter for precision measurement of powder feed rates in gms/minute or Lbs/hour.

• Electrical Specifications : 1 phase, 230V, 50Hz

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(IV) Specifications of Fully Integrated Part & Gun Manipulation system complete:

• Fully integrated, including gun (Robot), work piece (Turntable) manipulator and Servo track motion.

• Full integration capability with Plasma spray system

(a) Six Axis Robot :

• Robot should be of reputed make like ABB / KUKA

• 6 (Six) axis articulated Thermal Spray Robot

• Min 10 Kgs load capability

• 3 (Three) External axes capability

• Working range : 2400mm minimum

• Equipped with special hard ware & software for thermal spray process

• RIO Interface Board for direct high level communication on the RIO bus of thermal spray installation.

• Soft brake control software extension.

• Proper integration and interface to allow following process controls - Start/Stop plasma gun - Select plasma spraying recipe no. 1 … 99 - Start/ Stop cooling air - Start/Stop turntable and desired RPM set point - Position Turntable tilt - Position robot track - Set robot track traverse

• Electrical specifications : 3 Phase, 415V+10%, 50Hz+3% (b) Tilting Turntable :

• High precision & Heavy duty type

• Rotating and tilting capability to be fully integrated as external robot axes.

• Loading Capacity : 250 Kgs (approx)

• Face Plate Material : Stress relived Aluminum Alloy

• Face plate diameter 1000 mm & 1200mm (2 nos interchangeable)

• Tool Fixture : 4 slotted T – grooves for T Bolts

• Speed : 0 – 300 RPM in 1 RPM increments

• Accuracy : ± 1 RPM

• Sense of rotation CW/CCW

• Motor Control : Closed Loop

• Tilting Angle : 0 – 90 degrees

• Tilting Resolution : 0.1 degrees increments

• Tilting accuracy : 0.1 degrees repeatability

• Mechanical Accuracy : 0.1 mm total indicator run out

• Turn Table Height : 700mm (Approx)

• Error Supervision : RPM set point deviation

• Measuring System : resolver

• Tilt motion security : Hard/Software limits at <0° /> 90° (c) Servo Track for Robot :

• Servo track motion as an external robot axis to be closed loop controlled.

• The position control system to measure the motion of the traverse axis in increments and to maintain an accuracy and repeatability of ≤0.1mm

• Specially constructed for plasma environment and to be fully shielded against dust and electrical interference.

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• Traverse Speed : > 25 mm/sec

• Accuracy : ± 0.1 mm

• Motor control AC servo closed loop

• Drive mechanism : Ball screw & Guide rails

• Load Capacity : 350 Kgs (approx)

• Traverse Length : 1500 mm (approx)

• Unit to be equipped with Work piece cooling jets assembly including four venture type air jet nozzles on adjustable articulated arms and each venturi type air jet nozzle to be provided with a regulator for adjusting pressure from 0-8 bar.

• Unit to be equipped with an encoder and limit switches.

• The safety devices are to be interlocked with emergency stop circuit and cause a stop of the entire system if an error occurs.

(V) Specifications of Auxiliary Systems : (a) High Performance Scrubber: (wet scrubber desirable in place of

dry scrubber. To be quoted separately)

• Welded sheet metal construction, Cylindrical design

• Capacity : 15000 m³ / hr

• Power Capacity : 22 KW

• Residual dust content (max) : 50mg/ m³

• Suction fan speed (RPM) : 1400

• Electro- mechanical water level regulation (in case of wet scrubber)

• Suction system including movable suction hood.

• All the internal ducting in the integrated set up included (b) Sound Proof Booth :

• Sound Proof cabin providing a sound absorbing level at 80Dba measured at one meter from the cabin walls at closed door following DIN 45635 standards.

• Metallic modular & sealed panels structure.

• Length : 5000mm, Width : 3000mm, Height : 3000mm

• Single sliding door with 2000mm door clearance with two double glazing large observation windows (800mmx500mm) with one black glass adapted for plasma spray process.

• One of the two black panes installed in a hinged frame to allow free observation other thermal spray processes.

• One sound absorber installed on the cabin roof and on the air inlet

• One Sound absorber installed on the cabin roof and on the air outlet.

• Suction hood next to turn table for local extraction.

• Floor suction system

• Two adjustable fresh air inlet boxes installed inside cabin behind robot.

• Adequate internal cabin Lighting.

• Internal cabin ducting system.

• All the internal & external ducting, Cable trenches etc in the integrated set up.

(c) Electrical Distribution Unit :

• Stand-alone unit to house the main system disconnects circuit breakers, fuses as well as voltage conversion transformers and motor starters for the complete thermal spray set up.

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(VI) Specifications of On-Line Thermal Spray Monitoring Unit (Desirable):

• Provide precise, continuous, real-time and dependable detection and control of thermal spray coating processes through the characterization of spray temperature, velocity, intensity, geometry & position.

• Separate Sensor heads for Plasma Spray & HVOF/Powder Flame spray

• Data collection to include Particle velocity, Particle Temperature, Spray Plume intensity, spray Plume position, spray Plume geometry.

• Operating distance from spray gun : 200mm

• Camera Field vision : 380mm

• Measurement volume : 75 mm³

• Particle Temperature measurement range : 900 - 4000° C

• Particle Velocity measurement range : 5 -1000 m/sec

• Substrate Temperature measurement range : -18-530° C

GENERAL REQUIREMENTS 1. Electrical equipments suitable for operation on 415 volts ± 10 %, 3-phase, 50

cycles AC. Supply. 2. Requirement of isolation transformer and voltage stabilizer to be forwarded to

us for procurement from our side. 3. The equipment should be designed so as to provide for easy maintenance /

repair of all parts. 4. All components used for the equipment should be best of quality and of reputed

make. 5. Adequate protection should be provided for all components against possible

damages. 6. The equipment should be manufactured and processed in accordance with good

design and sound engineering practice and to the entire satisfaction of the inspection authority.

7. The equipment should be fitted permanently with a name plate at a visible place. The following information should be etched / engraved on the name plate.

♦ Nomenclature

♦ Section / Ref. / Part No. / Model

♦ Month and Year of manufacture

♦ Manufacturer's name and type

♦ Serial No.

♦ Supply order no. and date

♦ Origin 8. Warranty - The equipment should be under a warranty period of 12 months

from the date of commissioning against defective design, material, workmanship etc.

9. Name and address of the customers with whom machines of offered model is in operation for more than a year should be indicated. Customers' appreciation certificate if any is to be enclosed along with the offer. Quotation without furnishing of user's list as well as customers' feedback report may not be considered for acceptance.

10. Two sets of technical literature (in English) illustrating the design, operation and maintenance of the equipment & accessories should be forwarded along with the quotation.

11. Recommended spares (Mechanical, Electrical & Electronics) for two years trouble free running of the machine should be quoted. List of the items to be enclosed. (Desirable)- Itemized cost to be furnished.

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12. All the accessories including standard and optional should be quoted with itemised cost.

13. The machine should be inspected during Pre Dispatch Inspection at manufacturer's site as well as at our site during commissioning and installation.

14. Training on operation and maintenance to be imparted to our personnel during pre-dispatch inspection and commissioning.

15. Prove out of two components in support of accuracy should be carried out by the supplier at our site.

16. After sales service support for the offered machine should be clearly indicated. 17. Cost of AMC should be mentioned clearly as an option - Desirable. SPECIAL NOTE:

� The quotation should include specific answers strictly with respect to our tender specifications and specification deviation if any should be highlighted with clarifications.

� The supplier should furnish the quantitative values with respect to specified values in the technical specification of the quote clearly instead of mentioning “Complied”, “Agreed” or “Confirmed” etc., otherwise the tender quote is liable to be rejected.

� Points other than “ Desirable “ as mentioned above are essential in nature. � Offers not meeting essential requirement shall not be considered.