Integration and Testing of PSLV - ISRO · 2015. 12. 7. · mission (28x 21000 km). ... Chandrayaan and Mangalyaan missions both of which elevated India’s place among leading Space

Integration and Testing of PSLV Sub-assemblies for ISRO

Call for Expression of Interest

October 2015

VIKRAM SARABHAI SPACE CENTRE

THIRUVANANTHAPURAM


Vikram Sarabhai Space Centre Page 1

Contents ABBREVIATIONS .............................................................................................................. 2

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

1.1 PSLV .................................................................................................................. 3

2 Sub-Assemblies ............................................................................................................. 5

3 Scope of Work ............................................................................................................... 7

3.1 Decks, Housings, Brackets, Fasteners etc. ........................................................... 9

3.2 Flight hardware ................................................................................................... 9

3.3 Documents ........................................................................................................ 11

3.4 Harness Materials .............................................................................................. 11

3.5 Mock-up hardware ............................................................................................ 11

3.6 Preparation of Flight Structure ........................................................................... 12

3.7 Harnessing on Dummy Hardware ...................................................................... 12

3.8 Harness Transfer to Flight structure ................................................................... 12

3.9 Continuity & Isolation Checks ........................................................................... 12

3.10 Flight Packages Assembly ................................................................................. 13

3.11 Phase – I Checks ............................................................................................... 13

3.12 Final Assembly .................................................................................................. 13

3.13 Vibration Test.................................................................................................... 13

4 Responsibilities of Industry: ......................................................................................... 13

4.1 Vibration Shaker facility .................................................................................... 14

4.2 Man hour requirement ....................................................................................... 15

5 Responsibilities of VSSC ............................................................................................. 16

6 Insurance & Safety ....................................................................................................... 16

7 General terms and conditions ....................................................................................... 16

8 Basis of Short listing .................................................................................................... 17

ANNEXURE 1 ................................................................................................................... 18

Electrical harnessing details ............................................................................................ 18

ANNEXURE 2 ................................................................................................................... 19

Vibration Test Facility .................................................................................................... 19



ABBREVIATIONS

VSSC : Vikram Sarabhai Space Centre

PSLV-XL : Polar Satellite Launch Vehicle with Strapon Motors

MVIT : Mechanisms, Vehicle Integration &Testing Entity

TERLS : Thumba Equatorial Rocket Launching station.

PSOM : PSLV Strap-On Motor

PS1/PS2/PS3/PS4 : First/Second/Third/Fourth Stage of PSLV

EB : Equipment Bay

IS : Inter Stage (L: Lower, M: Middle, U: Upper)

CBS : Core Base Shroud

TF : Thrust Frame



1. Introduction

Vikram Sarabhai Space Centre (VSSC) is the lead centre responsible for realization of launch

vehicles. Realization of flight Sub-assemblies, integration (mechanical and electrical) and

check out of all Launch Vehicles of ISRO are presently being carried out at the centre. The

centre currently employs its in-house facilities at Valiamala & TERLS area for the activities.

Existing facilities at Valiamala and TERLS were established more than 25 years ago. The

current escalation in demand for launching more payloads has resulted in increased frequency

of PSLV launches per year which can be achieved only through maximum involvement from

Industry. Hence as per ISRO philosophy, VSSC has decided to outsource a part of integration

& testing activities so that the existing facilities and manpower can be maximally utilised for

development work of ISRO in connection with its future launch vehicle programmes.

1.1 PSLV

The Polar Satellite Launch Vehicle, PSLV is a Launch Vehicle developed and operated by

the Indian Space Research Organization (ISRO). Even though it was primarily developed to

launch Indian Remote Sensing (IRS) satellites into Orbits, owing to high success rates

associated with the Vehicle, it is also used to launch small-medium sized payload satellites

into Geostationary Transfer Orbit (GTO) and planar orbits having different inclinations as

well. PSLV has the capability to launch 170 kg in SSPO at 622 km and 1425 kg in sub GTO

mission (28x 21000 km).

With the repeated successful missions over the years PSLV has proven to be the operational

work horse vehicle of ISRO. The PSLV has a full-fledged end-to-end launch service

management and has launched numerous foreign and Indian satellites including several

dedicated commercial launches. PSLV has proven its worth in launching a variety of

satellites equipped to perform wide range of applications viz. communication, geographical

survey ,navigation, inter planetary missions etc. The same PSLV was successfully used for

Chandrayaan and Mangalyaan missions both of which elevated India’s place among leading

Space faring nations of the World.

There are currently three operational versions of the PSLV namely the PSLV Generic version

with S9 strapons , the PSLV-XL version with S12 strapons which carries more solid fuel in

its strap-on motors than the standard version and the PSLV Core-Alone version (PSLV CA)

without the six strap-on booster motors. All the three versions have proved to be unalloyed

successes.



The PSLV is a four stage vehicle with alternate solid and liquid propulsion modules. It has

gross length of 44 metres and lift off weight of approximately 300 tones. The first stage

employs solid-fuel rocket booster (S 139) and six strap-on motors (depending on the variant).

The second stage employs the Vikas engine of liquid propellant – Unsymmetrical Di-Methyl

Hydrazine (UDMH) as fuel and Nitrogen tetroxide (N2O4) as oxidizer. The third stage uses

solid propellant. The fourth stage of PSLV has a twin engine configuration with liquid

propellants N2O4 and MNO3 as fuel. The Satellite or payload is mounted over a Payload

Adaptor and is covered using Heat Shield which protects the spacecraft and vehicle

electronics during the vehicle’s ascent phase through the atmosphere.

Figure 1: PSLV Generic vehicle configuration with sub-assemblies for integration



2 Sub-Assemblies

The following sub-assemblies of PSLV are currently being realized by VSSC.

� Core Base Shroud (CBS)

� PSOM decks

� Inter Stage 1/2 Lower (IS 1/2L)

� Thrust Frame (TF)

� Inter Stage 2/3 Lower (IS 2/3L)

� PS3 Adaptor (PS3A)

� Equipment Bay (EB)

Total number of sub-assemblies: 7 Nos.

Out of the above seven sub-assemblies, the following five sub-assemblies undergo Vibration

tests as part of acceptance for flight use.

� CBS

� TF

� IS 2/3L

� PS3A

� EB

To meet the target of increased launch frequency of 6-8 flights of PSLV/year, it is decided to

outsource the responsibility of realizing and testing the above listed sub-assemblies to Indian

industry.



Views of few sub-assemblies are shown below.

Figure 2.1: CBS (PSLV)

2800 mm dia, 3000 mm height

Figure 2.2: PSOM (PSLV)


Figure 2.3: Thrust Frame (PSLV)


Figure 2.4: IS 2/3L (PSLV)


Figure 2.3: PS3 Adaptor (PSLV)


Figure 2.3: EB (PSLV)




3 Scope of Work

It is proposed to realize the sub-assemblies of PSLV including acceptance vibration testing at

the premises of the Industry. The steps towards implementing this involve:

� Integration, Testing and Delivery of sub-assemblies from the established/refurbished

facility.

� Establishment of new facility/Refurbishment of existing facility for Integration &

testing of PSLV Sub-assemblies.

The facility built/refurbished shall have the capacity to realize Sub-assemblies for 6-8

PSLV missions in a year and it is expected that supplier will support the production

over a period of 10 years(minimum).

To save time and effort, all Sub-assemblies are proposed to be transported from the Industry

to other centres of ISRO, for launch.

The flight harness is done on a Harness Mock up hardware, which is a replica of the flight

structure. The mock up hardware consists of all integration components assembled to it for

carrying out electrical harnessing. A typical flow chart for sub-assembly realization and

details of activities involved are given below.



Decks, Housings, Brackets, Fasteners, etc.

Document

Materials

Flight Hardware

Preparation of Flight Structure

Harnessing on Dummy Hardware

Dummy Hardware

Harness Transfer to Flight structure

Continuity & Isolation Checks

Flight Packages Assembly

Phase – 1 Checks

Vibration Test

Test Station

Test Facility

Test Station

Vibration Assembly

Harness Tester

Flight Packages

Stage Level Assembly

SUB-ASSEMBLY PRODUCTIONISATION PHASES

Flow Chart for Sub-assembly realization



3.1 Decks, Housings, Brackets, Fasteners etc.

Typical mechanical mountings on different sub-assemblies are shown above.

Harness clamps simulating flight packages are mounted on the decks. Required tie mounts

are assembled for arresting the wire harness. Flight harness is transferred to this flight item,

from mock up hardware.

3.2 Flight hardware

Typical flight structures are listed below. Preparation and testing of these structures by

integrating the mechanical elements, electrical harness, sensors, packages, and its final

acceptance testing as a sub-assembly is the scope of the work.

Fig. 3.2: CBS Housing deck Fig. 3.2: PSOM Deck Fig. 3.2: CBS Deck

Fig. 3.2.1: IS 1/2L



Flight hardwares are received from work centre. Pre-assembly and final assembly of flight

integration components are then carried out. Flight harness is then transferred from the mock

up hardware for further testing and delivery to SHAR

Fig. 3.2.2: EB

Fig. 3.2.3: PS3A



3.3 Documents

Documents (Configuration Controlled) are supplied for each sub-assembly preparation which

contains the details of all the mechanical & electrical activities. Harness documents are

provided for carrying out the electrical harnessing of the structure. Operational Log books are

also provided for carrying out harnessing, where all details of personnel’s like operators, QC

inspectors, supervisors, engineers etc are entered. All operations carried out are recorded in

real time, and it provides the details of components used for the activity, any observations/re-

works. This documentation provides easy traceability of the flight preparation activities.

3.4 Harness Materials

Harness materials are connectors, wires sleeves, ties for cable anchoring, sheaths, lacing

threads etc.

3.5 Mock-up hardware

Mock up hardware for harnessing will be made available for all Sub assemblies. It resembles

the flight configuration for all harnessing interfaces. Avionic packages and termination

connectors are simulated by connector mounted plates. Harnessing mock up of few sub

assemblies are as shown below:

Fig. 3.5.1: Dummy CBS

Fig. 3.5.2: Dummy IS Fig. 3.5.3: Dummy EB



Fig. 3.9.1: Continuity and Isolation

3.6 Preparation of Flight Structure

Pre assembly operations (metal cutting) are carried out on flight structure. All integration

components are then assembled and final torque is applied.

3.7 Harnessing on Dummy Hardware

Harnessing is carried out as per the VSSC document supplied.

3.8 Harness Transfer to Flight structure

After completion of harnessing on dummy structure, the same is transferred to the flight

sturcture. Avionic package connector plates are assembled to flight sturcture during harness

transfer. Harness transfer on EB structure is shown below.

3.9 Continuity & Isolation Checks

After completion of harness transfer, it is tested for continuity and isolation. A Harness Tester

of 20000 lines is used for the purpose (will be supplied by VSSC).

Fig. 3.5.2: Harness transfer to flight hardware



3.10 Flight Packages Assembly

After successful completion of continuity and isolation checks, the connector plates are

replaced by Avionic packages. The packages are assembled to decks temporarily with flight

fasteners. The harness connectors are also mated to packages.

3.11 Phase – I Checks

The sub assembly is powered and Electrical checks are carried out as per Check list using

Checkout system (delivered by VSSC).

3.12 Final Assembly

After successful completion of all Electrical checks, final torque is applied to all Avionic

packages and connectors using fasteners.

3.13 Vibration Test

The sub assembly is moved to Vibration facility and assembled to the vibration table using

identified interface fasteners. Tests are carried out as per the Flight acceptance test (FAT)

document along all three axes.

After completion of FAT the sub assembly is moved to preparation bay for containerization

and transportation to other ISRO centres for launch.

4 Responsibilities of Industry:

� Establishment of an exclusive Integration facility (air-conditioned) with plinth area of

1000 sq.m(minimum) and carpet area of 800 sq.m (minimum) and a storage area (Non

AC) of 400 sq m (minimum).

� Establishment of 160 KN vibration shaker facility. (Annexure 2)

� Integration, Testing and Delivery of sub-assemblies to meet the requirement of 6-8

PSLV’s per year.

� Maintenance and operation of Checkout systems for testing and procurement of

tools(Totalling 12 Crore), harness materials like cables, connectors, sheaths and other

consumables(from ISRO approved vendors), automatic harness tester for testing of

sub-assemblies(20000 lines) etc.

� Mobilization of skilled manpower.



The Integration facility shall have the following facilities:

� Air-conditioned assembly bay (23 degrees C) with a crane hook height of 8 m and a

high bay with crane hook height of 13m attached to it and crane capacity of 5 Tons.

The total plinth area shall be 1000 sq.m with a carpet area of 800 sq.m. The facility

shall have access to entry of VSSC trailers.

� Lightning protection and smoke detection system.

� Office space, bonded store, inspection facility etc.

� Three numbers of heavy duty motorized mechanical doors of large opening (8m x

12m) for entry of trailer.

� Fencing of area and establishment of an independent entry with access control and CC

TV monitoring is preferred.

� Establishment of auxiliary facilities, including Parking facility, generator room with

DG set of 75 KVA, UPS, electrical panel room etc.

4.1 Vibration Shaker facility

A vibration shaker facility with 160 KN capacity in an AC room is essential to test the sub-

assemblies. The details are mentioned in Annexure 2

Activities involved in sub-assembly realizing are:

� Harness model preparation, labelling, inspection and mechanical integration activities.

� Electrical Harnessing on mock-up structure (Annexure 1)

� Documentation

� Preparation of flight structure and transfer of harness.

� Continuity and isolation checks including online QC surveillance.

� Package inspection and assembly.

� Check out system readiness, check out preparation, check list etc.

� Electrical checks

� Viii) Vibration assembly

� xi) Test results preparation and presentation.

� Receipt and dispatch of hardware to VSSC/SHAR.



4.2 Man hour requirement

Indicative man hour requirement for each sub-assembly, based on the mentioned activities, is

estimated as follows.

PSLV Sub-assembly Man hours Man hours (Category wise)

Core Base Shroud(XL)

(including PSOM Decks) 4675

Engr - 500

Dip - 1275

Tech - 2900

Core Base Shroud

(core alone) 3200

Engr - 400

Dip - 900

Tech - 1900

1/2 L Interstage 735

Engr - 25

Dip - 200

Tech - 510

2/3 L Interstage 1015

Engr - 115

Dip - 300

Tech - 600

PS 3 Adaptor 1555

Engr - 220

Dip - 470

Tech - 865

Thrust Frame 1500

Engr - 220

Dip - 415

Tech - 760

EB + PS4 9500

Engr - 1000

Dip - 2500

Tech - 6000

The industry shall recruit/position trained manpower for carrying out the sub- assembly

integration. All technicians and QC supervisors have to mandatorily undergo and clear VSSC

In-house training course, the cost of which has to be borne by the industry.



5 Responsibilities of VSSC

� Transportation and delivery of harness mock-ups, support fixtures and flight hardware

to site.

� Positioning of Flight/related structures of PSLV

� Issue of Mechanical Integration components and avionic packages.

� Delivery of Checkout systems, harness tester and imported flight components.

� Issue of documents for harnessing, assembly and testing for each sub-assembly

� On-line random surveillance for quality assurance.

� Participation of experts during critical phase of electrical testing and review at site

� Transportation of sub-assemblies from the facility to ISRO premises for further

operations.

6 Insurance & Safety

The buildings built/refurbished shall conform to Industrial safety norms. Industry is

responsible for the safety of the facility including the sub-assemblies/equipments. The

industry shall keep the facility insured against any loss due to fire, explosion, earthquake,

flooding, theft, etc.

7 General terms and conditions

1. The interested supplier shall be required to make a presentation to ISRO covering the

following:

� Profile of the company

� Staff strength

� Engineering skills

� Past experience(relevant)

� Financial standing

� Facilities available/proposal to establish new facility with time line

2. Details of the land and building being offered for sub-assembly realization shall include

building cost/age, crane, air conditioning, approach road and other auxiliary systems.

3. Confirmation & commitment on execution time required.



4. The supplier shall not sub contract the works related to Integration & testing.

5. Industry should be a consistently profit making one and should have turnover of 50 crore

/year. Balance Sheet for 3 years may be supplied. Experience in similar related field will

be preferable.

6. Annexure 2 gives a summary of general terms & conditions.

8 Basis of Short listing

Final short listing of parties will be done on the basis on financial standing, facility

establishment, experience in relevant areas and employee strength etc. If required, a facility

inspection will be carried out by our team before selection of parties.



ANNEXURE 1

Electrical harnessing details

The Electrical harnessing activities of the sub-assembly that will be carried out by the

industry involve the following:

� QC inspection of the collected FIM material

� Wire/Cable preparations (cutting/stripping etc.)

� Crimping tool verification/setting/sample pull test

� Crimping (circular and D-type and DBAS and other type connectors)

� QC inspection of the crimped joint ( 100% inspection)

� Inserting in the shell and verification

� Cable bunching/routing/lacing/labelling

� Shield soldering

� Isolation and continuity checks

� QC inspection of harnessing process and on the finished sub-assemblies.

� Hook soldering any as per the document

� Testing of continuity of the connections, isolation checks and functional checks as per

the checklist supplied.



ANNEXURE 2

Vibration Test Facility

A vibration shaker facility with the following specifications is required for the Flight

Acceptance Testing of the integrated sub-assemblies

• 160 KN shaker

• Slip-table for lateral axis test with 2800 PCD interface

• Conical expander for thrust axis test with 2800mm PCD interface

• Air conditioned high bay with overhead crane of 5-tonnes capacity

• DG supply