� ला� ़मा अनुसंधान सं� थानINSTITUTE FOR PLASMA RESEARCH

परमाणु ऊजा� �वभाग, भारत सरकार का एक सहायता �ा� तसं�थान

An Aided Institute of Department of Atomic Energy,

Government of India

इ��दरा पुल के पास, भाट, गांधीनगर – 382 428 भारतदरूभाष: (079) 2396 2020/2021/2028

फै�स: 91-079-23962277

वेब: www.ipr.res.in

NEAR INDIRA BRIDGE, BHATDIST. GANDHINAGAR - 382 428 (INDIA)

Phone: (079) 2396 2020/2021/2028 Fax : 91-079-23962277

Web : www.ipr.res.in

ENQUIRY

ENQUIRY NO : IPR/EQL/17-18/568

Date : 28-02-2018

Due on : 05-04-2018 by 1:00 PM IST

Please send your offer in sealed envelope specifying Enquiry No, Date & Due Date, ALONG

WITH your credentials for the following items:

Important Note:

Please note that e-mail quotations are not acceptable however you may send your queries (if

any) to localpurchase@ipr.res.in

Please ensure your sealed quotation reaches this office not later than above mentioned due

date and time.

Kindly go through the following documents properly before quoting which are available on the

IPR web portal i.e., http://www.ipr.res.in/documents/tender_terms.html / attached herewith.

1) Instructions to the bidders & Terms and conditions (refer Form No: IPR-LP-01.V3)

2) Bidding format

GST for Goods and Services (IGST/CGST/SGST TAX BENEFITS): Please refer clause no: 8

of Form No: IPR-LP-01.V3

QUOTATION SHOULD BE ADDRESSED TO PURCHASE OFFICER ONLY

Sr No

Description Quantity

1 Mechanical design, fabrication, testing and supply of 2-stream (helium/2-

phase N2) vacuum-brazed Al-plate-fin heat exchanger (HE2)

1.0 Nos.

Note: 80% of order value will be made against delivery of material

at IPR site and its verification by IPR representative. Balance

20% will be made within 30 days from the date of acceptance

and on receipt of Performance Bank Guarantee for 10% of

the order value from SBI/nationalized/scheduled bank

(Scheduled banks acceptable to IPR are Axis Bank, HDFC

Bank, ICICI Bank and IDBI Bank) valid throughout the

warranty period.

Please quote with complete technical details (Technical

compliance sheet and product data sheet).

Encl: As per attachment. Sd/-

Mr. D. Ramesh

PDF processed with CutePDF evaluation edition www.CutePDF.com

Purchase Officer-II

Information to Vendors: We are working towards a single platform for our future

requirement. Hence, please refer IPR website i.e,

http://www.ipr.res.in/documents/tendersenq.html for our future requirement.

TECHNICAL SPECIFICATION

Mechanical design, fabrication, testing and supply of

2-stream (helium/2-phase N2) vacuum-brazed Al-

plate-fin heat exchanger (HE2)

2

Contents Page Number

Introduction ........................................................................................................................................... 3 1.

Eligibility criteria for vendor to submit the Quotation ........................ Error! Bookmark not defined. 2.

Scope ..................................................................................................................................................... 3 3.

3.1 Design ........................................................................................................................................... 3

3.2 Documents for design approval .................................................................................................... 3

3.3 Manufacturing ............................................................................................................................... 4

3.4 Tests, inspection and acceptance criteria ...................................................................................... 4

Shop test and acceptance criteria .......................................................................................... 4 3.4.1

Site test and acceptance criteria ............................................................................................ 4 3.4.2

Inspection by IPR .................................................................................................................. 5 3.4.3

3.5 Documentations to supply ............................................................................................................. 5

3.6 Packing and Forwarding ............................................................................................................... 5

Specification of material of different parts ........................................................................................... 5 4.

Heat exchanger dimensions, drawings and configuration details ......................................................... 6 5.

5.1 Dimensions and configuration ...................................................................................................... 6

5.2 Drawings: ...................................................................................................................................... 9

3

Introduction 1.Thermo-hydraulic design of liquid nitrogen-cooled compact plate-fin heat exchanger, to be used

in the helium refrigerator/liquefier (HRL) plant, has been done. This, initially will also be used in

the turbine test facility to cool helium gas from about 80 to about 30 K. This will be, later, after

turbine tests, used in the helium plant for cooling of helium gas from ~100 K to ~80 K using LN2.

Heat exchanger is named as HE2. This will be installed vertically, so that, Liquid N2 (LN2) will

enter from bottom of it and vapor N2 (VN2) will come out at top of it. This will be tested at low

temperature at IPR. Relevant design information, drawing and dimensions have been included in

this document. Based on these information, supplier shall do mechanical design and supplier may

change overall dimensions of the heat exchanger except the fin parameters, layer arrangement,

width and length of thermal zone. The changes, due to mechanical design, are unlikely to change

the thermo-hydraulic performance of the heat exchanger. Before going for manufacturing,

supplier must get the design and drawings approved from IPR. The details of the scope and

technical specifications with drawings are given in this document.

Scope 2.

This purchase order covers mechanical design, documentation, manufacturing, testing,

inspection, packing, forwarding, supply and guarantee/warrantee of one 2-stream (2-phase

N2/helium) vacuum brazed aluminum plate fin compact heat exchanger. More details are given

as follows.

2.1 Design

The supplier shall carry out the entire mechanical design of this heat exchanger and the supplier

shall be responsible for the mechanical performance as well as mechanical stability of this whole

unit. The design shall be carried out for the design data given in Table-1.The mechanical design

of heat exchanger shall be done as per code of ASME section VIII Div-I and ALPEMA. As an

additional requirement in the view of cryogenic service, the supplier may include any other

relevant code that will be used in designing. This exchanger shall be provided with suitable

support structure handling, assembly and installation inside the vacuum chamber and it shall be

approved from IPR before manufacturing. Drawings are attached with part numbering and

names.

2.2 Documents for design approval

Following documents shall be submitted for the approval of the purchaser prior to the fabrication:

1. Material test report: Mill test certificate or random sampling and testing at NABL certified Labs. 2. Brazing and welding procedure and qualification certificate along with the brazing operator and

welder qualification certificate as per ASME section-IX. 3. Pneumatic and helium leak test procedure. 4. Mechanical design and fabrication drawings with stacking arrangement. 5. Quality assurance plan clearly indicating material procurement, manufacturing/fabrication stages,

inspection and testing along with different hold points and witness points.

4

2.3 Manufacturing

All the parts of heat exchanger have to be fabricated as per the materials mentioned in this

document. If supplier wants to use alternative material, supplier shall get approval from IPR and

for this, it must provide sufficient information to justify why it can’t use specified material and

that the alternative material is suitable for the heat exchanger. Sufficient quality assurance and

quality control plans (QA and QC) should be implemented throughout the work. All parts, except

header tanks, nozzles and support structures, all other parts should be joined by vacuum brazing

in a vacuum furnace. The header tanks, nozzles and support structures can be joined by welding

outside the vacuum furnace. Due to the manufacturing processes, there should not be flow

maldistribution, restrictions in the flow paths and incomplete brazing between mating surfaces.

For this, adequate QA and QC should be followed.

2.4 Tests, inspection and acceptance criteria

Shop test and acceptance criteria 2.4.1

1. Under water pressure test should be done for all the streams individually at pressure and

procedure, as per design code, with dry nitrogen. There should not be any visible water bubble

coming out from the heat exchanger surfaces.

2. Helium leak (Vacuum and pressure) test at room temperature for inter-stream and between heat

exchanger and atmosphere. In vacuum mode, paths of all streams in the heat exchanger will be in

vacuum and externally helium will be sprayed. In pressure mode, paths of all streams will be

pressurized with helium, where, hot helium path to 15 bar and cold N2 path to 2 bar. For inter-

stream leak check, flow passage of cold N2 stream will be in vacuum and hot helium stream will

be pressurized with helium to the pressure 15 bar. For all the above cases, leak rates should be, <

5x10-6 mbar.l/s (local) and < 5x10-5 mbar.l/s( global leak leak rate). In case of the inter-stream, as

local leak test is not possible, only global leak test will be done.

3. Manufactured heat exchanger dimension check.

These above tests will be considered as pre-dispatch inspection test and acceptance will be given

based on the satisfactory test results.

Site test and acceptance criteria 2.4.2

Following acceptance tests will be done at site (IPR) and acceptance certificate will be issued if

all the acceptance test results satisfy the technical requirements of this document. In case of any

deviation, supplier has to rectify/remake at its own cost, including the packing, transport to its

factory and back to IPR, if required. Installation and conducting the test are in the scope of IPR.

All consumables and equipments for these tests are in the scope of IPR.

1. Helium leak test at room temperature: This is same as mentioned in section 3.3.1.2

2. Helium leak test at low temperature: Both streams will be pressurized to the pressures as

mentioned for pressure mode in section 3.3.1.2 and leaks from heat exchanger to outside will be

measured. Here global leak rate can be checked as local leak check will be difficult. Inter-stream

leak check will be done in the way mentioned in section 3.3.1.2.

5

Supplier personnel may witness these tests at its own cost.

All helium leak tests (tests at shop and tests at site) should be done by mass spectrometer

helium leak detector.

Inspection by IPR 2.4.3

IPR personnel and/or IPR approved third party will visit and witness at supplier’s factory site at

least two times for following instances:

1. During assembly of parts and vacuum brazing of full assembled parts. This will include the

dimension checking of different parts of heat exchanger.

2. Pressure test and helium leak test during pre-dispatch inspection test

For above tests supplier should accordingly arrange the visits and tests for IPR personnel.

2.5 Documentations to supply

The vendor shall submit 2 (two) copies of bound data folders containing the following

information: 1. Mechanical Design Calculations of the Heat Exchanger with relevant code (ASME Code and

equivalent international code) references.

2. Certified material test reports showing chemical analysis, physical/ mechanical properties of all

the materials used in the fabrication of the heat exchanger.

3. Pressure test report.

4. Detail component design drawings and fabrication drawings.

5. Any further documents as required for testing at IPR and maintenance requirements.

2.6 Packing, Forwarding and delivery schedule

The heat exchanger shall be thoroughly cleaned and pressurized and filled with dry Nitrogen at 2

bar (abs) and sealed before packing. Mechanical surfaces, flanges etc. shall be protected by using

wooden plank along with rubber sheets to avoid any damage in transit. The supplier should take

all responsibility to supply the heat exchanger at IPR without any damage. It should be delivered

within 2 months from the date of dwg approval. Dwgs should be submitted to IPR within 2

weeks from the date of PO acceptance.

Specification of material of different parts 3.

(Nomenclature is as per ASME standard) 1. Header tank ( Half pipe ) : SB 241 5052

2. Closing plate of header : SB 221 5052

3. Inlet/Outlet pipe : SB 241 5052

4. Edge Bar : SB 221 3003

5. Cap Sheet : SB 209 3003

6. Brazing sheet / Parting Sheet : SB 209 4104/3003

6

7. Heat transfer fin (thermal Zone) : SB 209 3003

8. Distributer fin : SB 209 3003

Heat exchanger dimensions, drawings and configuration details 4.

Table-1 gives the details of dimensions and configurations. Table-2 gives the part

numbering, description and materials. Drawing-1 and 2, Drawing 3A and 3B gives the

details of different parts (Refer section 4.2).

4.1 Dimensions and configuration

Table-1: 2-stream (2-phase N2/helium) heat exchanger (HE-LN2-PTF)

Abbreviated name of Heat exchanger

HE

Type of heat exchanger

Vacuum Brazed Plate- Fin (Offset or Serrated Fins)

Counter Flow Heat Exchanger

Material Aluminum alloy as mentioned in section 3.

Quantity of heat exchanger to be supplied 1 No

Service fluid Nitrogen (Liquid+vapor) / Helium Gas

Maximum allowable helium leak rate(see details of section < 5x10-6

mbar. l/s locally and < 5x10-5

mbar.ltr/s globally

Length (including top and bottom distributors, header tanks

and end pipes or nozzles)

1440 +/- 100 mm

Cold stream (C) and hot stream (H) arrangements HCHHCHHCHHCHHCHHCH

Location and orientation where it will be installed Vertically within vacuum chamber. LN2 will enter from

bottom side and VN2 will come out at the top.

Design Code ASME or equivalent International Code

Transition Joint Al/ SS-304L Not in the scope of supplier

Fluid Stream-1(Hot He) Stream-2( Cold

LN2+VN2)

No. of Layers 12 6

Edge bar length (Drawing 3A and 3B) 955 mm(part-5A) 1040 mm(part-5B)

Edge bar width 15 mm 15 mm

Edge bar thickness As per plate spacing As per plate spacing

Details of

Thermal Zone

Fin Type Serrated Serrated

Plate spacing (Fin height) 6.5 mm 9.5 mm

Fin thickness 0.2 mm 0.2 mm

Fin characteristic

length

5 mm 5 mm

Fin density 709 fins/m(18 fins/inch) 709 fins/m (18

fins/inch)

Thermal zone length (Without

distributer, header, pipes and top and

bottom gaps)

850 mm 850 mm

Thermal zone width

( with edge bars)

200 mm 200 mm

Thermal zone depth (Stack height 189 mm 189 mm

7

including cap sheets)

Details of

Distributor part

(entry and exit

have same

dimensions)

*

Fin Type (perforation diameter and

pitch are as per supplier)

Plain Perforated Plain Perforated

Plate spacing 6.5 mm 9.5 mm

Fin thickness 0.2 mm 0.2 mm

Perforation Diameter As per supplier As per supplier

Fin density 315 fins/m (8 fins/inch) 315 fins/m (8

fins/inch)

Distributor Length (excluding closing

bar and gap between thermal zone and

distributor)

70 mm 85 mm

Closing bar width 185 mm --

Closing bar length 15 mm --

Inlet and outlet

header tanks (half

pipe cut

lengthwise)

Outer diameter 101.6 mm 114.3 mm

Thickness 5.74 mm 6.02 mm

Length of Pipe 189 mm 189 mm

Closing plate thickness 8 mm 8 mm

Inlet and Outlet

Pipe Size

Length 100 mm 100 mm

Outer diameter 60.3 mm Inlet: 33.401 mm

Outlet: 60.3 mm

Thickness 5.16 mm Inlet: 3.38 mm

Outlet: 5.16 mm

Inlet/Outlet Orientation Side entry/exit(Diagonal type) Direct entry/exit

Design Temperature (K) 320 to 80 K 320 to 80 K

Design Pressure 20 bar, absolute 5 bar, absolute

Test Pressure As per ASME or international

code

As per ASME or

international code

Cap Sheet Thickness/width/length 10 mm/121 mm/835 mm

Parting sheet Thickness/width/length 2 mm/121 mm/835 mm

Gap-A and Gap-B (Drawing 3A) 15 mm and 10 mm

Gap-C between Thermal Zone and Distributor(same at top

and bottom) (Drawing 3A & 3B)

10 mm

Gap-D (side entry/exit distributor ) (Drawing 3A) 5 mm

*(Inlet and outlet distributor and header tank dimensions are same for each stream)

8

Table-2: Part No. (See drawing-1 to 3) with names and materials

CONFIDENTIALITY AND NONDISCLOSURE AGREEMENT

IPR’s this heat exchanger design information should not be used for any other purpose than what

is mentioned in this technical specification without consent of IPR.

No. of

different

Parts.

Names of different Part Material

1 Cap Sheet SB 209 3003

2 Thermal Zone fins (Heat transfer fins) SB 209 3003

3 Top distributor (fins) SB 209 3003

4 Bottom distributor (fins) SB 209 3003

5 Edge bar SB 221 3003

5A Edge bar (Hot layer) SB 221 3003

5B Edge bar (Cold layer) SB 221 3003

6 Brazing sheet/Parting Sheet/Brazing Sheet SB 209 4104/3003/4104

7,8,9,10 Header Tank SB 241 5052

11 Inlet and Outlet Pipes SB 241 5052

12 End Edge bar SB 221 3003

13 Closing plate of header tank SB 221 5052

9

4.2 Drawings (not to scale):

Drawing-1: Drawing for heat exchanger HE with part numbers

10

Drawing-2: Different Views of heat exchanger HE

11

Drawing-3A: Details of hot layer for Heat exchanger HE

12

Drawing-3B: Details of cold layer for Heat exchanger HE