TECHNICAL SPECIFICATION

FOR
Design, Fabrication and Supply of Low Temperature Part of Helium
Turbine-2

For
IPR, Bhat, Gandhinagar, Gujarat, PIN-382428

1
Contents: Page No.
1. Introduction 3
2. Scope of Work and supply 3
3. List of different parts and material requirements 5
4. Conceptual drawing and critical dimensions provided by IPR 7
5. Design, Analysis, Drawing and Documentation Requirements 11
6. Material Test Requirements 14
7. Factory Acceptance Test 14
8. Items to Deliver 15
9. Site Acceptance test at IPR 16
10. Time Schedule of Work and Supply 16
11. Vendor Compliance Sheet 18

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1. Introduction
This document contains Technical Specifications for design, fabrication, test and supply of low
temperature parts (also named as LT parts or LT subassembly) for indigenous, helium turbine of
indigenous helium refrigerator/liquefier (HRL) plant, being developed at IPR, Bhat, Gandhinagar. This
HRL plant has 3 imported helium turbines called as Turbine-1, 2 and 3. These turbines are assembled
vertically with the vacuum chamber of the cold box of the HRL plant. Most of the parts of turbine stay
out of vacuum chamber and at room temperature.

IPR has been developing indigenous helium turbine for last few years. Based on the assembly
concept, the indigenous turbine will have 3 subassemblies: 1) warm end housing (also called as top
cover plate subassembly), which will contain speed sensor and port to feed helium gas for bearing, 2)
bearing housing ( also called as middle part subassembly) with bearings, brake mechanism, shaft,
turbine wheel and blades and 3) cold end housing (also called as bottom low temperature (LT) part
subassembly) having nozzle, diffuser, inlet and outlet process pipes, flange to assemble turbine with the
cold box. Top cover plate and middle part stay in the room temperature and outside vacuum chamber
and LT part stays inside the vacuum chamber and at low temperature. IPR has presently taken up
indigenous development for turbine-2. All three subassemblies of indigenous turbine are at different
stage of development work, which are being developed at IPR, Bhat, Gandhinagar. The indigenous
turbine development work for indigenous HRL plant is taken up to make India self-reliant on
Cryogenics Turbine Technology.

This document will give different dimensional requirements and design requirements of LT
part of Indigenous Turbine-2. Based on these information, design and fabrication have to be done, so
that, LT part can be properly assembled with the middle part of Turbine-2 and port of the cold box. The
flange of LT part is fitted with flange of port of cold box. Middle part is fitted on the flange of this LT
part and is bolted with o-ring for leak tight sealing. So this LT part should have a flange with O-ring
groove and O-ring to assemble with the port of cold box. This LT part has a circular disc with a number
of nozzles to convert helium pressure to velocity so that helium can strike the blades of the turbine
wheel at high speed. By this, the energy of fluid is transferred to the turbine wheel and then to the shaft.
This LT part should be designed in such a way that there is sufficient thermal resistance against heat
transfer from the room temperature flange of LT part to the low temperature process helium gas, flowing
in the turbine. For turbine-2, the inlet and outlet process design helium temperatures are 15 and 10 K
respectively and inlet and outlet pressures are: ~6 bar (a) and 1.3 bar (a). More details are given in the
design requirement section.

1 set of LT subassembly which will have type-1 (normal precision) and type-2 (high
precision) deliverables. Accordingly, later, in this document, these are named as type-1
deliverables and type-2 deliverables. Except tolerances, all other requirements for both type of
deliverables are same.

2. Scope of work and supply

The vendor shall analyse the conceptual drawings and design requirements mentioned in this
document and do the detailed design and analysis, fabrication, factory acceptance test and
delivery at IPR. The details of the work and supply are as below.

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a. Analyse the interface between the middle part of the indigenous turbine and the
LT subassembly based on the information provided in this document and
design the different parts of the LT subassembly to satisfy the technical
specifications of Turibne-2 and requirements of this document.
b. Make the design document and drawings for above works including fabrication
and assembly method and send it to IPR for review.
c. Revise the design and analysis based on the review comments of IPR, if any
and make the fabrication drawing and get these approved from IPR.
d. Procure the materials of different parts required for both type of deliverables
and provide the material test certificate for review and approval of IPR.
e. Fabricate different parts and measure the dimensions using CMM (coordinate
measuring machine). The tolerances for critical dimensions for type-1 and type-
2 deliverables shall be as per table-2. Other dimensions, not mentioned in this
table, shall have tolerances as per the outcome of the design and analysis work.
f. Assemble all parts and measure the dimension of assembled LT subassembly
for both deliverables using CMM.
g. Make dummy shaft with diameter and length similar to what is there in the
indigenous turbine-2. At the bottom end there should be a solid structure, whose
outer dimension will be equal to the outer dimension of the wheel with blades
of turbine-2. This is required only to check, if the required gap between nozzle
and blades is there and if the vertical position of the nozzle parts are proper,
etc., after fabrication and assembly of LT parts. This shaft should have a
threaded part which can be useful for making it vertically up and down during
gap measurement. Make a proper fixture (It can be a small rectangular plate
with threaded hole at the centre and two hole at two ends to fix on the LT
subassembly by bolting) to fix this dummy shaft on the LT subassembly and to
allow to measure the interfacing dimensions easily. This is required for bot type
of deliverables.
h. Make cover plates to fix it on the top of the LT subassemblies for pressure test
and leak test.
i. Make 2 vertical support stands and 2 horizontal support stands. These will be
needed during assembly, disassembly, pressure test and leak tests. These should
be made to keep the middle part of the turbine along with LT subassembly
safely in vertical or horizontal position during assembly/disassembly with LT
part at IPR.
j. Make the pressure test and leak test and get the reports approved by IPR.
k. After getting dispatch clearance from IPR, do the proper packing and supply
the assembled component (LT subassembly) and other items to IPR.
l. IPR will do the measurement of dimensions, pressure test and leak test as part
of site acceptance test. The vendor shall visit IPR at its own cost to witness site
acceptance test. After successful completion of SAT, IPR will accept the
component, else vendor can take back the component(s) for alteration and
resubmission. All these should be completed, within the given time schedule
for delivery.

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3. List of different parts and material requirements

Table-1 gives the list of names of different elements (see Fig-1 to 4) to be designed and
manufactured to get the assembled LT part of the turbine-2. This is based on the concept and
its drawing for LT subassembly given in this document by IPR.

Table-1 includes also the material list and functions briefly. This list is as per the conceptual
drawing provided here. This list may get changed during design. After final design, a revised
list with functions and type of material has to be provided in the design report by the vendor.

Table-1: List of elements with its function, which have to be designed and manufactured for
LT part of turbine-2 (see the drawings to identify the elements).

Sl. Name of Function of the element Type of

No element of material
. LT
subassembly
1 Outer flange It is to hold the inner flange of LT subassembly SS304L
by bolting. It holds the middle part subassembly
of the turbine by bolting (using stator bolts). The
complete turbine is fitted on the cold box using
this outer flange by bolting. O-rings in the O-ring
grooves will provide leak tight sealing.
2 O-rings Different O-rings will be used to provide leak Appropriat
tight sealing at room temperature. e material
2 O-rings (1. between flange of nozzle housing as per
and outer flange and 2. between dummy cover design
plate and flange of nozzle housing) are required
for test and assembly at vendor site for each LT
assembly. 2nd one will be used further in the
assembly between middle part subassembly and
LT part. So the dimensions of O-ring groove in
the dummy cover plate and on the interfacing
surface should be same.
3 Nozzle This includes nozzle, its cover plate, header for SS304L
assembly helium gas feeding to nozzle, diffuser, etc.
4 Nozzle Within this housing nozzle parts, diffuser, inlet
Housing gas header and insulation are assembled. It
includes a flange, which sits on the outer flange
and the middle part of the turbine sits on this
flange. This provides longer conduction path for
heat leak to process fluid. Inlet/outlet process
pipes are also connected at the bottom of this
housing
5 Thermal To provide thermal resistance for heat transfer by PU
Insulation occupying the fluid space, which otherwise can (Polyureth
lead to convection heat transfer. ane ) or
equivalent

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 material.
Equivalent
material
has to be
justified
by the
vendor.
6 The inlet To supply the process fluid to the turbine SS304L
process pipe
7 The outlet To take out the process fluid from the turbine SS304L
process pipe
8 Dummy To cover the top of the LT part to hold the SS304L/S
cover plate pneumatic pressure during pressure test and leak S304
test
9 Dummy shaft To check the radial gap between wheel and nozzle SS304L/S
with solid after fabrication and assembly of LT parts. This S304/AL-
outline of will also help to check if the surface of the flange alloy
wheel and of the nozzle housing is perpendicular to the
blade tips central axis of the nozzle assembly. A solid
outline representing the profile of the diameter of
the tip of blades should be made. Along the depth
of the shaft axis, this tip diameter changes. In this
document, only max. And min. diameters are
given. More details of the variation will be given
during execution of the work.
The fabricated solid outline should have
diameter deviation < +/- 20 micron compared
to the dimension given by IPR.
10 Fixture of To hold the dummy shaft and fix it on the LT
dummy shaft subassembly so that, one can easily measure the SS304L/S
relative position of the LT parts with respect to S304
shaft, wheel and blade tip. One can measure, if the
axis of this shaft is at an angle to the central axis
of the nozzle assembly and accordingly one can
find in which part correction is required.
Support Support stands are required to keep the LT SS304L/S
11 stands subassembly vertically and cartridge subassembly S304
horizontally safely. This will be necessary during
assembly, disassembly, pressure tests, etc., on a
working table of height about 0.75 m. At least 2
support stands have to be made for each set of LT
subassembly. The horizontal stand will be used
during assembly of the cartridge and LT part at
IPR.
12 Dummy For fixing the dummy cover plate on the flange of SS304L/S
screws the nozzle housing. 4 no. of such screws have to S304
be made for each set of LT subassembly. It should
have O-ring to seal with the flange of the nozzle
housing.

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 13 Stator screws The middle part, top plate and LT part have to be SS304L/S
assembled together by these screws to make a S304
complete turbine. 4 such screws will have to be
made for each LT subassembly. Appropriate
threaded holes should be included in the LT part.

4. Conceptual drawing and critical dimensions provided by IPR

The drawings showing different elements and dimensions of conceptual LT

subassembly are given in Fig-1. The surfaces and parts of middle part
subassembly of turbine which will interface with the LT subassembly are shown
in Fig-2. Critical dimensions are given in table-2.

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Fig-1: Drawing with dimensions of the conceptual LT subassembly of turbine-2.
The dimensions of nozzle assembly and other parts may change after the design
work.

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Fig-2: Drawing with dimensions of the interfacing surfaces of the bottom of the
middle part subassembly of turbine-2.These surfaces will interface with the LT
subassembly.

Critical dimensions: These are the dimensions of elements of LT parts, which

interface with the indigenous turbine middle part during turbine assembly. If
these dimensions are not proper then interfacing will not be proper, which can

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lead to performance degradation. These interfacing dimensions should be
designed and manufactured properly. These dimensions and its tolerances are
mentioned for both type of deliverables in table-2.

Table-2: Critical dimensions and required tolerances. These tolerances are required on the LT
part subassembly which will interface with the middle part subassembly of turbine. This LT
part subassembly dimensions will be decided by the design work, which is a part of this tender.

Sl. No. Dimension description Dimensions in Required Required

(Refer Fig-1 and 2) mm of the Maximum Maximum
existing parts tolerances in tolerances in
which will micron for micron for
interface with interfacing interfacing
the LT parts LT part for LT part for
type-1 type-2
deliverables deliverables
1 Outer diameter of turbine 105 +/- 100 +/- 100
middle part
2 Outer diameter of the O-ring 80 +/-100 +/-50
groove where O-ring sits and
it seals tightly by interfacing
with the LT part.
3 Width and depth of above O- 2.5 x 2 +/- 100 +/-50
ring groove
4 The outer diameter of the 72 +/-100 +/-20
slanted surface on the bottom
of the middle part (beside the
O-ring groove)
5 The inner diameter of the 70 +/- 100 +/-20
slanted surface on the bottom
of the middle part (beside the
O-ring groove)
6 The max/min diameter of the 22/8 +/-100 +/-20
tip of the turbine blades.
7 The axial depth of the blade 15 +/- 100 +/-20
tip with maximum diameter
from the outer surface.
8 The axial depth of the blade 21 +/-100 +/-20
tip with minimum diameter
from the outer surface.
9 Diameter (d) of the hole and 6 x 90 +/-100 +/-100
its PCD (D) for fitting of stator
screws. These stator screws
are used for assembly of LT
part, middle part and top cover
plate: d x D

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 10 Outer Diameter of the outer 150 +/-100 +/-100
flange of the LT subassembly
11 Dimension of the O-ring 118 x 4 x 3 +/-100 +/-100
groove of the outer flange:
outer diameter x width x depth
12 Diameter (d) of the hole and 12 x 132 +/-100 +/-100
its PCD (D) for fitting of outer
flange with the port of the cold
box: d x D

Notes for table-2:

a) As turbine is a critical and confidential equipment, exact dimensions are

not mentioned in this document. But, mentioned dimensions are quite
closer to the actual dimensions with about +/- 10% variation. The exact
dimensions and any missed out dimensions, which are required for design
of LT parts, will be communicated by IPR to the vendor during execution
of the work. And vendor should not use those exact dimensions for any
other purpose than this work without permission from IPR.
b) All circular parts (including circular arrangement of bolt holes) of LT
subassembly, whose central axis position, as per design has to match with
that of the shaft of the cartridge, should have eccentricity less than 20
micron.
c) Thickness of the top cover plate (not shown in the drawing) of the turbine
is 23 mm. This is required in deciding the length of the stator screw. Stator
screw is used to hold all 3 parts of turbine tightly during assembly.
d) Standard sizes and practices (for flanges, screws, bolts, O-ring grooves, bolt
holes, etc) should be used as much as possible. The dimensions given here
for LT subassembly should not be considered exact one. Based on design
and standard practice, dimensions of parts have to be decided and vendor
has to get these approved from IPR before fabrication.

5. Design, analysis, drawing and documentation requirements

The process fluid conditions and other design parameters for which turbine-2 is being designed,
are given in table-3. Main design requirements for LT subassembly are given in table-4.
Considering the requirements and parameters given in table-2 and 3, design of LT subassembly
should be done.

Table-3: Process fluid parameters and other design parameters of indigenous

turbine-2
Sl. No Parameter Values/description
1 Helium flow rate, g/s 45
2 Inlet pressure in bar (a) 5.9

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 3 Inlet temperature in K 15
4 Outlet pressure in bar (a) 1.3
5 Outlet temperature in K ~10
6 Isentropic efficiency in % 70
7 Nominal speed in Hz 2700
8 Off-nominal Operation 8 to 325
temperature range in K
9 Design pressure, for which 20
structures have been made, in
bar (a)
10 Pneumatic Test pressure, in 22
bar(a)
11 Turbine installation Vertical
orientation

Table-4: Main design requirements for LT parts. Design should also consider the process
parameters and other design parameters of turbine-2 mentioned in table-2 and other parts of
this document.
Sl. No Parameter Values Remark, if any
1 Heat load on the low < 20 W Or it should be
temperature process fluid due such that, the
to the LT subassembly designed
(excluding shaft thermal isentropic
conduction and other heat efficiency will be
leaks due to middle part >70% and water
subassembly) condensation on
the outer flange of
the LT part should
not be there.
2 Vertical weight, need to be ~20 Kg Due to this
carried by the top surface of loading, other
the LT part due to cartridge parts of LT
assembly work on it. subassembly will
also get affected
which should be
included in the
design.
3 Maximum internal pressure it 20 bar (a)
may need to bear during fault
condition of turbine operation
4 Test pressure with air or 22 bar (a). At this
helium pressure no
visible damage or
leak should be
there.

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 5 Nozzle sizes, angles and Design has to be Design should
dimensions of other parts of done to satisfy the also be consistent
LT subassembly requirements of with the middle
isentropic part of turbne-2.
efficiency of
> 70% and other
parameters given
in this document.
Design should
ensure uniformity
in flow, velocity
and direction of
helium around the
periphery of the
blade tips of shaft.
6 Local helium leak rate to the ≤ 5 x 10-5 mbar
atmosphere while internal ltr/s
helium pressure 14 bar (a) at
room temperature
7 Thermal stress During nominal
and cool-down
condition, it
should be able to
sustain thermal
stresses.

5.1 Documentation requirements

Following documents have to be prepared by the vendor during execution of
this work.
a) The document having the design and analysis details for LT parts with shaft,
wheel and blades of the turbine. It should contain also the assembly/disassembly
procedure for LT subassembly.
b) Conceptual drawings with dimensions should be made based on the above
design and analysis.
c) Document containing the CFD analysis for flow through the nozzles, diffusers,
inlet/outlet pipes, etc (excluding analysis for rotational parts). This document
should also include heat load analysis to find external heat load on the process
fluid.
d) Fabrication drawings should be made based on the final design and analysis
documentation. It should be made separately, one set for type-1 (100 micron
tolerance) and another set for type-2 (20 micron tolerance) parts.
e) CFD analysis including rotational parts (Shaft, wheel, blades and fluid), to find
isentropic efficiency of the expansion process,

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 5.2 Document and drawing review and approval

Vendor shall provide above documents of a) to d) of section 5.1 to IPR for review.
Based on IPR’s comments/suggestions, these documents shall be revised by the vendor and
send to IPR for review and approval. After approval of fabrication drawings, fabrication work
shall be started. The CFD analysis document mentioned in e) will be given to IPR for review
at the time, when factory acceptance test reports will be given to IPR for review.

All the documents mentioned above, from a) to e), will be given to IPR in 2 sets as hard
copies along with LT subassemblies after satisfactory factory acceptance test. Soft copies also
have to be submitted to IPR in pdf/doc/dwg format.

6. Material test requirements before fabrication

Materials procured for making LT part and dummy parts (excluding insulation material) should
be tested for its chemical composition and test reports should be sent to IPR for review and
approval.

7. Factory Acceptance test

Following inspection/tests to be made at the factory site after fabrication of all parts.

a. Check the dimensions and these should be as per the fabrication drawings, for
each element and assembly.
b. Pressure (internal) test at 22 bar (a) with air/nitrogen/helium to check pressure
sustenance of the LT subassembly at room temperature. No observable damage
should be there due to this pressure.
c. Helium local leak test with internal pressure at 14 bar (a) and leak rate to the
atmosphere should be < 5 x10-5 mbarltr/s.

The reports of inspection/test will be sent by the vendor to IPR for review and approval. IPR
representative will visit vendor workshop to witness the above tests. IPR will bear the expenses
of visit of its personnel. During execution of the work, IPR representative may also visit vendor
workshop with prior intimation to see the progress of the work.

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8. 1 Set of Helium expansion Turbine parts – Design, Fabrication and
supply of Low Temperature Part of Helium Turbine2 consisting of
the following:

a) All parts as mentioned in table-5 shall be supplied as fabricated parts.

Table-5: List of fabricated items, vendor has to supply to IPR

Sl. No. Item name and Quantity

description
Type-1 deliverables
1 LT subassembly 1 set
(This will contain nozzle
assembly, housing for
nozzle, inlet/outlet process
pipe, outer flange, dummy
cover plate with its fitting
screws)
2 Stator Screws for fitting 4 no.
top cover plate, middle
part and LT part together.
3 Vertical Support stands 1 no.
4 Horizontal Support stands 1 no.
5 Dummy shaft with wheel 1 no.
6 Fixture for shaft 1 no
Type-2 deliverables
1 LT subassembly 1 set
(This will contain nozzle
assembly, housing for
nozzle, inlet/outlet process
pipe, outer flange, dummy
cover plate with its fitting
screws)
2 Stator Screws for fitting 4 no.
top cover plate, middle
part and LT part together.
3 Vertical Support stands 1 no.
4 Horizontal Support stands 1 no.
5 Dummy shaft with wheel 1 no.
6 Fixture for shaft 1 no

b) 2 copies of all 5 documents, as mentioned in bullets under 5.1 (a) to (e) in

section-5, have to be supplied to IPR as hard copy. These also have to be sent
to IPR as soft copy in pdf/doc/dwg format.
c) All inspection/test reports.
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9. Site Acceptance Test at IPR

The same tests as mentioned in the FAT will be carried out at IPR
site by IPR for both deliverables. The vendor has to visit IPR at its own
cost to witness site acceptance test. If site acceptance test results are not
complying to the requirements, then, vendor may take back faulty item (s),
for correction and return back at its own cost for site acceptance test again
at IPR. All these should be completed within the time period given in this
document in section-11.

10. Time Schedule of Work and Supply

1. Design, analysis and making fabrication drawings have to be completed and

documents mentioned in bullet a) to d) of section-5 will be supplied to IPR for
review as soft copies by email within 90 calendar days from the date of acceptance
of work order (WO).
2. IPR has to review these documents and give its comments, if any, within 15
calendar days.
3. The vendor shall submit the revised documents including fabrication drawing
mentioned in a) to d) to IPR within 15 calendar days for review and approval
4. IPR has to review these documents and give its approval within 15 calendar days.
5. Raw material procurement, its test, fabrication of all parts, FAT and delivery of all
deliverables have to be completed within 180 calendar days from the date of IPR’s
approval of drawings.
6. Site Acceptance test at IPR has to be completed by IPR within 10 calendar days
from the date of receipt of material at IPR.

Total time period of this work is 325 calendar days (~11 months)

Table-8 below gives the Estimation of time for execution of the work in
tabular form.
Table-8: Estimation of time for execution of the work
Sr. Work Time period as No. of
no. calender days from the
date of work order (T0)
1. Date of purchase order T0
2. Design, analysis and making fabrication drawings have T0+90 calendar days
to be completed and documents mentioned in bullet a)
to d) of section-5 will be supplied to IPR for review.

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3. IPR has to review these document and give its T0+105 calendar days
comments, if any
4 The vendor shall submit the revised documents T0+120 calendar days
including fabrication drawing mentioned in a) to d) to
IPR for review and approval.
5 IPR will review and give its approval T0+135 calendar days
6 Raw material procurement, its test, fabrication of all T0+315 calendar days
parts, FAT and delivery of all deliverables
7 Site Acceptance test at IPR Type-1 material received at T0+325 calendar days
IPR site

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11. Vendor Compliance sheet

Vendor shall fill table-9 and send it along with the bid.

Table-9: Vendor Compliance requirements

Sr. PR requirements Vendor Response

No.

1 Vendor should be able to do CFD-based and FEM-

based flow, stress and thermal conduction
analysis. Vendor must confirm it.
2 Vendor should be able to do the pressure test and
helium leak test (using He MSLD or thermal
conductivity based leak detector). Vendor must
confirm it.
3 Vendor should be able to do all
machining/fabrication works as per the shapes and
precision requirements of this job and tolerances
mentioned for different parts. Vendor must
confirm it.
4 Does the vendor agree to all Technical
specification?
5 Does the vendor agree to all commercial terms and
conditions?

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