Page: 1 of 31

.Technical Specifications for Manufacturing of hull and integration of Automotive & Non-automotive aggregates for WHAP
(No. VRDE/WV/WHAP/HULL/811 Dt. 21st Feb 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 8x8 driveline 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).

Page: 2 of 31 3. SCOPE OF WORK Sr. Specifications / Requirements No 3.1 Manufacturing as per Para 4.1 i. Hull envelop and hull system aggregates ii. Mounting blocks / brackets for Automotive and nonautomotive aggregates including add-on armour, power pack, drive line, shock resistance seats, other equipments, etc. . iii. Drivers, stick commanders, troopers, Engine & transmission hatches, ballistic louvers for cooling air intake and exhaust iv. Anti-surge vane including actuating mechanism v. Towing and lifting hooks vi. Bulkheads vii. Ballistic louvers for cooling and air intake & exhaust system viii. Rear door with ramp ix. Water Tanks x. Maintenance ports xi. Battery compartment xii. Miscellaneous items, etc 3.2 Design, Development and Integration as per Para 4.2 i. Fuel System ii. Pneumatic System iii. Hydraulic System iv. Actuation system for louvers, hatches & ramp v. Drivers Station vi. Stick Commanders station vii. Commanders & Gunners station(for RCWS version ) viii. Winch System ix. HVAC System x. NVH Design xi. Electrical / Electronic System, etc 3.3 Assembly / Integration as per Para 4.3 i. Integrated Power Pack (IPP) ii. Under Chassis Driveline (UCD) iii. 30 mm turret (Proto-I) iv. RCWS (Proto-II) v. Hydro-jets vi. Crew seats vii. Vision Devices viii. Composite Armour ix. Winch system x. GPS System xi. NBC System Remarks by DA

Page: 3 of 31 xii. xiii. Electrical and electronic systems Combat support equipment like water tanks, firing ports, fire extinguishers, shovel, Special Purpose Tools and Accessories (SPTA), wooden log, pickets, personal combat kits, etc

3.4 Testing as per Para 4.9 i. 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. ii. iii. Detailed Design report for systems / subsystems designed by DA Process documents for manufactured systems/ subsystems GA, Assy & sub-assy & part drawings for all systems manufactured/designed & developed by DA as a part of this development contract User, technical and Maintenance Manuals of all systems & sub-systems sourced / developed by DA Test Certificates for materials / items / components Quality check documents pertaining to end of assembly line tests

iv. v. vi.

3.6 Deliverables i. One bare hull for blast testing ( without machining) ii. Quantity one prototype fitted with 30 mm turret for designers trial iii. 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 trials DA will associate with Designers and User assisted technical trials and will be responsible for in-situ repair, maintenance, minor modifications of systems designed and developed as a part of this work contract. For all manufactured parts, in-situ support will be provided by DA on case to case basis. 3.8 Warranty The DA will provide warranty coverage of one year from the date of acceptance (not applicable for bare hull) for all the systems / sub systems manufactured and developed.

Page: 4 of 31 4. SYSTEM DETAILS 4.1 Manufacturing Sr. No.

4.1.1

Specifications / Requirements

Remarks By DA

The approximate dimensions of the bare hull are as follows: Length : 7900 mm Width : 2800 mm Height : 1650 mm Please ref GA layout enclosed at Annexure A Estimated finished weight of Steel Armoured Hull with steel structure will be of the order of 3800 to 4000 kg. (Without any fitments) Material of hull structure/space frame - TISCON 500D / Equivalent Steel with standard sections. Hull envelope-Monocoque construction Plate 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. The design of hull will be provided by VRDE. DA will evaluate the design from manufacturability point of view and suggest suitable changes. Thereafter manufacturing drawings will be prepared by DA based on corrected inputs. DA will provide mounting arrangement for add-on armour as per design and scheme from VRDE and will carry out its assembly on the vehicle. The hull envelope and structure will be welded using suitable welding process so that the Heat Affected Zone (HAZ) will not exceed the temperature beyond the specified limit provided by armour / steel supplier. The distortion levels - not to exceed 1.5 mm/m. The hull envelope will be subjected to shot peening / copper slag blasting.

4.1.2

4.1.3

4.1.4

4.1.5

4.1.6

4.1.7 4.1.8

Page: 5 of 31
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 as given in the hull drawings. For prototype 1 machining will be done for Turret Ring of 30 mm Gun and Rotary Base Junction location. The base turret ring will be integrated with hull top plate as per drawing. For prototype 2, machining will be done for RCWS mounting. The accuracy of the machining should be as per requirement. Alternatively DA can opt for the procedure as given in 4.1.22 below. Cutting of profiles for openings of rear door, hatches, vision devices and firing ports will be carried out using plasma / laser cutting or any other advance process. Standard Engineering practices will be followed for manufacturing of all necessary mounting brackets/attachment devices of hull. Weight optimization will be done at all places and wherever feasible light weight materials will be used so that weight penalty is reduced. Maintenance ports are at the bottom of the hull in engine compartment. Bulkhead will be provided with appropriate thermal insulation material for Integrated Power Pack as per NVH studies by DA. Profile along with full design of the cover of ballistic louvers for cooling air intake and exhaust system will be provided by VRDE in consultation with IPP supplier. Mounting brackets and maintenance ports on the bulkhead Skydesk foot pads will be used for shock attenuation Ramp actuation system including all hydraulic components and seals for rear door will be sourced as per the dimensioning, rating and mounting details provided by VRDE The hull envelope will be spray painted with Zinc rich primer followed by camouflage painting as per standard procedure

4.1.10

4.1.11

4.1.12

4.1.13

4.1.14

4.1.15 4.1.16 4.1.17

4.1.18

Page: 6 of 31
4.1.19

The first hull will be manufactured as a bare hull for blast testing without spray painting and machining. Based out the outcome of blast testing, there may be requirement to carry out certain repair works/local modifications in the same bare hull and subject it to retest for blast. DA will carry out such changes. The cost of all freight charges for bare hull for blast testing will be borne by VRDE. The second hull will be manufactured incorporating shape modifications if any based on blast testing of bare hull and will be integrated with all automotive and non-automotive aggregates. The third hull be manufactured and integrated with all automotive and non-automotive aggregates based upon design improvements obtained from designers trials of second hull prototype. Suitable manufacturing processes will be evolved by DA and approval for the same to be obtained from VRDE. The DA will have facility for cold bending of the armour plates. The minimum bending radius should be in the range of 8xt 12xt (t= thickness of the plate). The prototypes are amphibious hence all the openings need to be sealed for water ingress. The seals will be sourced by DA from the vendor identified by VRDE or DA may also suggest alternate source with approval from VRDE Since the hull is for combat applications with amphibious capability, there is a need to properly evolve armour welding procedures including edge preparations, WPS, welder qualifications and weld joints testing. Suitable fixtures for handling the jobs will be developed by DA. The hull envelope will be tested by DA for water ingress by submerging it in static water tank with blinds fitted on openings. All tests should be conducted in presence of VRDE Reps

4.1.20

4.1.21

4.1.22

4.1.23

4.1.24

4.1.25

4.1.26

4.1.27

Page: 7 of 31 4.2 Design, Development and Integration

4.2.1 Design & development of fuel system

Sr. No.

Specifications / Requirements

Remarks By DA

(i)

Design and manufacturing of 250 litre (approx.) capacity fuel tanks- qty 02 nos. The shape of the fuel tanks will be given by VRDE. DA will manufacture the fuel tanks as per IS standard. Assembly of fuel tanks to the hull envelope 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 material used to prevent blast of fuel tanks against Small Arms fire. - Source of supply M/s Meera International, Delhi, OR M/s DVM International, Delhi OR M/s TAML, Bangalore

(ii)

(iii) (iv)

4.2.2 Design & development of Hydraulic systems Sr. No. (i)

Specifications / Requirements
Provision of hydraulic drive for winch system and rear door ramp. The details like location, ratings, speed of operation etc will be provided by VRDE. Also the hydraulic actuators will be selected for actuation of IPP hatch, Anti-surge vane and louver mechanism. Suitable hydraulic system (either one or multiple) will be selected for these operations based on the feasibility study by DA. This involves design & development of a hydraulic circuit / accumulator base system for the requirements of various hydraulic consumers. (Excluding hydraulic system for cooling fans of Integrated Power pack). - Development of necessary interface hoses, control valves and other hydraulic aggregates - Circuit diagram and system logic will be provided by VRDE.

Remarks By DA

(ii)

Page: 8 of 31 (iii) Integration of all hydraulic components and reservoirs at suitable location Development of man machine interfaces (Display & controls) for various actuated devices at suitable locations

(iv)

4.2.3 Design & development of ballistic louvers actuating mechanism and automatic engine shutdown Sr. No. (i)

Specifications / Requirements
DA will cater for design interface requirement under NBC threat for cooling air intake and exhaust louvers, actuating mechanism for engine compartment hatches (hydraulic system as mentioned above) with necessary interface for engine shutdown & re-actuation mechanism. The interface will be provided through an electronic signal from the auto shutdown interface unit. The display and control units will be provided at the suitable locations for the same.

Remarks By DA

4.2.4 Development of Drivers, commanders and gunners stations Sr. No.

Specifications / Requirements
Drivers station The location of Drivers Station will be on the right hand side of the vehicle adjacent to the IPP DA will carry out ergonomic design of vehicle controls like dashboard, steering, brake pedal, accelerator pedal, gear shift lever, parking brake and drive controls like differential lock, drive selection lever, hydrojets joystick, hydraulic controls, etc. Development of Vehicle Dashboard Assembly of drivers hatch and vision devices Assembly of blast resistant seat Stick Commanders station

Remarks By DA

(i)

(ii)

(iii) (iv) (v)

(i)

The commanders station is located just behind the drivers station

Page: 9 of 31 (ii) (iii) Assembly of hatch and vision devices Assembly of blast resistant seat Commander & Gunners stationsThis is only for proto II which is mounted with RCWS. For 30mm turret version (proto I), the commander & gunners stations will be integral part of turret.

(i)

The commander & gunners station will be at center of the vehicle. Assembly of hatches, blast resistant seats, vision devices and RCWS control consoles and display Integration of RCWS (Proto II) Integration of 30 mm turret system for Proto-I. DA will carry out mechanical fitment of RBJ, harness preparation on stator side & turret integration on vehicle and associate in functional testing.

(ii)

(iii) (iv)

4.2.5 Development of Troopers compartment Sr. No. (i)

Specifications / Requirements
The troopers vehicle compartment will be at the rear of the

Remarks By DA

(ii) (iii) (iv) (v) (vi)

Mounting / integration of blast resistant seats Assembly of firing ports Mounting of periscopes / vision devices Assembly of escape hatches Assembly of water tanks, stowage boxes and other combat loads Assembly of hydraulically actuated rear door ramp Assembly of skydesk pads at appropriate locations

(vii) (viii)

Page: 10 of 31

4.2.6 Design for NVH, HVAC and NBC system. Development of HVAC & NBC systems Sr. No.

Specifications / Requirements
HVAC system DA will be responsible for design and development of HVAC system for the prototypes The operating temperatures will be -20 C to +55 C Minimum temperature drop 10 C with pull down time of 20 min in Static vehicle condition. Suitable heating arrangement to be provided for low temperature environment. Development of ducting and ports Interfacing of HVAC control unit at drivers station Insulation lining to be provided with a suitable thickness to achieve required cooling effectiveness. The material should be such that minimum thickness (of the order of 10 mm or less) is achieved. NVH Design DA will carry out NVH studies of vehicle based on which DA will suggest and implement necessary measures. DA will also provide design and development of engine bulkheads, localized noise insulation for engine compartment. NBC system NBC system will be installed in proto-II Louvers & engine shutdown mechanism with its integration and Interlock harness will be developed by DA to the logic provided by VRDE. BC filtration system without harnesses will be provided by VRDE. Harnesses will be developed by DA. DA will develop interface unit for Auto-shutdown for various units under NBC threat. For this, VRDE will provide necessary specifications of various interfaces. Also harness from this unit to various control elements will be developed by DA.

Remarks By DA

(i) (ii) (iii) (iv)

(v) (vi) (vii)

(i)

(i) (iii)

(iv)

(v)

Page: 11 of 31 4.2.7 Design & development of electrical / electronic system Sr. No. (i)

Specifications / Requirements
DA will prepare a detailed design on Vetronics systems based on circuit diagrams prepared by VRDE. DA will procure/develop the subsystem/items as per the list provided by VRDE. Additional/extra subsystem / items required to ensure overall system functionality, will also be procured/developed by DA. Integration of all equipment, systems, subsystems, development of heat shrinkable cable harnesses with MIL 38999 series II connectors, harness layout & integration / interface with systems will be carried out by DA. - The electrical system will comply with MIL 1275D - The MOTS (Military Off The Shelf) equipments should comply with JSS 55555 and MIL 461F Integration of FIM equipments, systems, subsystems, preparation of cable harnesses with connectors (where ever required), harness layout & integration / interface with other systems will be carried out by DA. The harnesses developed by DA shall be MIL qualified. All components, devices shall be of MOTS (Military Off The Shelf) items. Provision of limit switches for all hatches and interlocking them with NBC auto shutdown mechanism and provision of signal at RBJ for fire inhibit. Provision of Battery, battery isolator switch & battery contactor by DA (qty per prototype given below) -HBL make BR 140- 12 VDC/160AH 02 nos -Battery isolator switch 01 no & Starter contactor 01 no Alternator - FIM by VRDE, 10kW / 28V harness. DC without

Remarks By DA

(ii)

(iii)

(iv)

(v)

(vi)

(ix)

Power Distribution Box (PDB) Development by DA. Tease-free, trip-free, push/pull on/off thermal circuit breakers of proper current rating as fuses should be used . PDB should have enough spare power taps. Harness layout plan in 3D model will be prepared by DA in consultation with VRDE.

(x)

Page: 12 of 31 (xi) Cable Harnesses - The electrical cable harnesses will be developed and assembled on the vehicle by DA as per VRDE approved plan. Cable harness manufacturing to comply with - STD JSS 6145-04 Engine Starting System - Starter motor will be FIM by VRDE. Starting system components along with harness will be provided by DA. Provision for slave starting will be made by DA. Power pack Electronics & Electrical sensors will be provided by VRDE, DA will carry out interfacing of those sensors & inputs/outputs with dashboard with appropriate harnessing. Vehicle Dashboard - Dashboard design specifications will be prepared by VRDE. Detailed design and development of dash board will be done by DA . - The dashboard will be ruggedized industrial grade unit. - Functional and compliance testing of dash board will be responsibility of DA. Lighting system Military Off- the -shelf items to be sourced by DA after approval from VRDE. 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 Periscope Vision System - FIM by VRDE, DA will carry out integration & mechanical fitment. GPS Navigation System - FIM by VRDE, DA will carry out integration & mechanical fitment. RCWS will be FIM , DA will carry out assembly & integration of RCWS and commander & gunners station (For proto II). 30mm turret will be FIM. DA will carry out assembly of 30mm turret and RBJ (For proto I).

(xii)

(xiii)

(xiv)

(xv)

(xvi)

(xvii)

(xviii) (xix)

Page: 13 of 31 4.3 ASSEMBLY

4.3.1 Integrated Power Pack (IPP) Sr. No. (i)

Specifications / Requirements
Integration of Air intake system with necessary mounting brackets for pre cleaner filter (on bulk-head) with interface for NBC air input, HVAC air supply to crew compartment. Suitable interface will be provided for dust ejection system Assembly of mounts for IPP Interface between hydraulic system, hydraulic winch and anti-surge vane actuators Integration of filter, FOL supply lines with electrical preheating provision. Assembly of HVAC system with necessary mounting arrangement for compressor, evaporator (Minimum three), condenser (packaged with cooling radiator cores) Integration of ballistic louvers with necessary opening and closing mechanism for cooling system and exhaust system Integration of bulkhead incorporated with inspection ports. NBC sealing shall be provided for isolation of engine compartment from rest of vehicle Integration of maintenance / accessibility ports at bottom of hull in IPP compartment. Assembly and integration of all manufactured subsystems mentioned under the manufacturing head above

Remarks By DA

(ii) (iii) (iv)

(v)

(vi)

(vii)

(ix)

(x)

(xi)

4.3.2 Under Chassis Driveline (UCD) (i) Integration of transfer case on hull with proper water and environmental sealing. Integration of differentials on hull (Qty 4 Nos)

(ii)

Page: 14 of 31 (iii) Integration of independent double wishbone suspension for front two axles Integration of trailing arm suspension system to the rear two axles Integration of steering system consisting of steering pump, steering column and steering linkages etc. Provision of hydraulic lines from steering pump to steering gear box and return line. Interface of pneumatic line between compressor and air tanks. Integration of pneumatic lines from air tanks to wheel ends. Integration of drive engagement / dis engagement lever / pneumatic actuators / push button for selection of HighLow and for 8x8 / 8x6 / 8x4 and amphibious drive engagement. Interfacing of differential lock and mounting of its lever in drivers station. Appropriate display for the above shall be included in driver console. Integration of ABS, CTIS controls / display at Drivers station Integration of Gear shift lever of automatic transmission at suitable location in drivers station. Interfacing of parking brake system and mounting of lever at drivers station Integration of bump / rebound stations. stoppers on all wheel

(iv)

(v)

(vi)

(vii)

(viii)

(ix)

(x)

(xi)

(xii)

Integration of Brake system on the vehicle with necessary mounting brackets. Assembly of Wheels Assembly of CTIS and ABS air tanks in the hull

(xiii) (xiv)

4.3.3 Hydrojets Hydrojets will be connected with mechanical drive system from last axle (i) Integration of Amphibious drive transmission consisting of splitter gear box (01 No), Angle gear box (02 nos) and driveshaft assemblies on the vehicle hull Qty 2 Nos. hydro-jets will be integrated at the rear of the vehicle

(ii)

Page: 15 of 31 (iii) DA will make provision of proper sealing for all openings so as to meet the amphibian capability Integration of hydro-jet control joystick and control panel at drivers station Assembly of Anti-surge vane with actuating mechanism for operation by driver Integration of electrically (03 Nos) & mechanically (01 No) operated bilge pumps at suitable locations inside the hull Interfacing of electrical harness from electrically operated bilge pumps with control console at Drivers station

(iv)

(v)

(vi)

(vii)

4.3.4 Winch system Hydraulically actuated winch to be mounted on front side of the vehicle for selfrecovery (i) (ii) The capacity of the winch will be around 10 ton Interfacing of hydraulic lines for actuation of winch system from IPP hydraulic circuit / a separate hydraulic source Interfacing of winch controls at drivers station Provision of Armour protection hood for protection of winch

(iii) (iv)

4.3.5 Integrated Vehicle Electronics Architecture (IVEA) (i) (ii) Required for prototype II. It will be FIM by VRDE DA will provide requisite inputs (Interface Control Document) 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) (ii) Required for prototype -II Mechanical integration & power cable harness to be developed by DA.

Page: 16 of 31

4.3.7 Integrated Fire Detection & Suppression System (IFDSS) (i) (ii) (iii) Required for prototype -II Complete IFDSS system with harnesses will be provided by VRDE. DA will execute assembly and integration of IFDSS.

4.3.8 Integrated Crew Vision System (ICVS) (i) (ii) Required for prototype 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 be provided 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 scope of work. Detail assembly plan will be prepared by DA which will be reviewed and approved by VRDE.

Page: 17 of 31

4.4 List of Items to be Procured / Developed by DA Sr. No. Nomenclature 4.4.1 Steel Armour of 5 mm and 6.5 mm thickness for manufacturing for qty 03 hulls Structural Steel for manufacturing of 03 hulls & Assembly / Sub-assembly integration for 02 Prototypes Stiffener plates (10 15 mm thick) Welding consumable & Fasteners. Anti-explosion material -To be quoted as optional Qty As required, Material -Miilux of 400 450 BHN/equivalent As required, TISCON 500D/equivalent As required As required As required Remarks By DA

4.4.2

4.4.3

4.4.4

4.4.5

Materials for fabrication/manufacture Lot and assembly of mounting brackets and miscellaneous items mentioned in the scope Shock Attenuation foot pads (skydesk) - To be quoted as optional -Blast resistant Seats for driver, stick commander & Crew (08 nos) -Commander & gunner (for RCWS version only) - Entire seat package to be quoted as optional Dash Board design and development including sensor interfaces and front panel displays as per scope Fuel system aggregates Hydraulic System aggregates Pump Interfacing unit for hydraulic system for winch, anti-surge vane and ramp Aggregates of drivers , commander, troopers station as per scope Bulkheads for thermal and noise isolation for engine compartment and NVH aggregates for engine and other parts based on NVH study As required, Make - M/s MKU, Kanpur 2 Sets 1 Set, Make - Jankel , UK 2 Nos

4.4.6

4.4.7

4.4.8

4.4.9 4.4.10 4.4.11

2 Sets 2 Sets 2 Sets

4.4.12

2 Sets

4.4.13

2 Sets

Page: 18 of 31 4.4.14 Ballistic louvers, hatches, rear door ramp with actuator as per VRDE specifications Brake & accelerator pedals Mounting accessories for Hydrojet system Winch System (10 ton capacity, hydraulically operated) Design and development of HVAC System Manufacturing of various brackets and other utilities as per scope Realisation of subsystem to hull interfaces on case to case basis as per para no 4.3.1 (i) Engine starting system excluding starter motor Harness integration for ICVS (proto II) Power distribution box (PDB) Heat shrinkable cable harnesses with MIL 38999 Series II connectors Lighting control panel & light control box (LCB) Main Head light Head light with Blackout door LED Dome light LED Marker light LED Reversing light Fog light Inspection lamp assy with sockets Horn 2 Sets

4.4.15 4.4.16

2 Sets 2 Sets

4.4.17 4.4.18 4.4.19 4.4.20

2 Nos 2 Nos lot At actuals

4.4.21

2 Sets

4.4.22 4.4.23 4.4.24

1 No 2 Nos 2 Sets

4.4.25

2 Sets

4.4.26 4.4.27 4.4.28 4.4.29 4.4.30 4.4.31 4.4.32 4.4.33

2 Sets 2 Sets 20 Nos. 14 Nos. 4 Nos. 4 Nos 12 Nos. 2 Nos

Page: 19 of 31

4.5 List of Free Issue Material (FIM) by VRDE Sr. No. Nomenclature 4.5.1 Integrated Power Pack (as mounted on sub frame) consisting of Engine, Transmission, Air Intake, exhaust and Remote liquid Cooling System with accessories Under Chassis Drive line consisting of Axles with independent Suspension, Transfer Case, Differentials, propeller and drive shafts, steering system, brake system with ABS, Wheels, Tyres with Run Flat Inserts, CTIS system, and Amphibious drive system Qty 2 Sets Remarks By DA

4.5.2

2 Sets

4.5.3 4.5.4

Hydrojets with controls and accessories 4 Nos. (2 sets) Add-on / composite Armour for two As prototypes required Vision Systems for Driver, Commander, stick Commander, Gunner & Crew compartment Remotely Controlled Weapon Station (RCWS) for proto II 30 mm turret system with RBJ for proto I Biological and Chemical (BC) filtration system Alternator and starter motor (part of IPP) Power pack E & E System including sensors GPS Navigation System NBC instrumentation (Proto II) Drivers Day & Night vision system (Proto II) 2 sets

4.5.5

4.5.6

1 no.

4.5.7

1 no.

4.5.8

1 Set

4.5.9 4.5.10

2 nos. 2 sets

4.5.11 4.5.12 4.5.13

2 Nos. 1 Set 1 No.

Page: 20 of 31 4.5.14 Integrated Crew Vision System ICVS (Proto II) 1 set -

4.5.15

Integrated Fire Detection & Suppression 1 set System (IFDSS)- (Proto II) Auxiliary Power Unit (Proto II) Integrated Vehicle Electronics Architecture (IVEA)- (Proto II) Turret ring for hull for 30 mm (Proto I) 1 No. 1 No.

4.5.16 4.5.17

4.5.18

2 No

Page: 21 of 31

4.6 Timelines Sr. No. Activity Duration (months) D D1= D + 2 D2 = D1+ 2 D3 = D2 + 2 D4= D3 + 3 D5= D4 + 1 D6= D5 + 2 D7= D6 + 1 D8= D7 + 1 D9= D8 + 2 D10= D9 + 1 D11= D10 + 3 D12= D11 + 1 D13= D12 + 1 D14= D13 + 1 D15= D14 + 1 Total
(Durat ion)

Remarks By DA

4.6.1 4.6.2 4.6.3 4.6.4 4.6.5 4.6.6 4.6.7 4.6.8 4.6.9 4.6.10 4.6.11 4.6.12 4.6.13 4.6.14 4.6.15 4.6.16

Placement of Development Contract Design Finalisation for First Bare Hull Manufacture of First Bare Hull (add two months) Design Finalisation of Second Hull Manufacturing of Second Hull Testing of Second Hull Integration of Automotive Aggregates Integration of Non-Automotive Aggregates ATP of First WHAP prototype Designers trials at VRDE Design updating if any for Third Hull Manufacturing of Third Hull Testing of Third Hull Integration of Automotive Aggregates Integration of Non-Automotive Aggregates ATP of Second WHAP prototype

0 2 5 7 10 11 13 14 15 17 18 21 22 23 24 25

4.7 Proposed Payment Terms & Conditions Sr. No. 4.7.1 Proposed Payment Terms & Conditions 30% of total order value be paid on submission of Design for Manufacturability Report within 3 months from the d ate of placement of supply order against submission of Bank Guarantee Remarks By DA

Page: 22 of 31 4.7.2 30% of the total order value will be paid on completion of inspection, acceptance and delivery of First prototype. 30% of total order value plus 100%taxes & duties will be paid after inspection, acceptance and delivery of Second prototype. Balance 10% of total order value covering warranty period will be paid on expiry of warranty period of second prototype OR on submission of BG, covering warranty period Advance payment will be made against proper bank guarantee from Nationalized bank for 110% of the advance claimed. If the contract is terminated due to default of the Contractor, the advanced amount would be deemed as interest bearing advance at a prevailing bank rate which will be compounded quarterly and will be recovered from the Contractor. The vendors should quote as per the specimen / template enclosed at Para 4.10 FIM Will be issued by VRDE as and when required in a staggered manner. The total cost of the FIM is Rs 450 lakhs (approx.) for which the contractor will have to provide Bank Guarantee to equal cost of the store, valid till stores are in their possession, to safeguard the Govt interest. F.O.R VRDE, Ahmednagar

4.7.3

4.7.4

4.7.5

4.7.6

4.7.7 4.7.8

4.7.9

4.8 General Points Sr. No.

Specifications / Requirements

Remarks By DA

4.8.1 Operating environment : Following are the specifications for operation of WHAP (i) (ii) (iii) (iv) (v) (vi) Operating temperature Storage Temperature Altitude : -20 C to +55 C : -40 C to +70 C

: Up to 4000 m above sea level

Humidity : 5-95% RH Vibration (Veh mounted equipments) : 1.5 g pk-pk, 8 500 Hz levels Shock (Veh mounted equipments) : Half sine shock pulse, 11 ms duration, 15 g peak

4.8.2 Miscellaneous items

Page: 23 of 31 DA will provide tool kit with each prototype consisting of items like Lifting jacks, fuses, spanner kit, essential spares of electrical system, gauges, etc 4.8.3 Workmanship (i) The workmanship should be in accordance with the accepted engineering and production standards of the industry so as to ensure operation of the prototypes under severe combat environment. Metal having pitted or corroded surfaces are not acceptable. Shearing and chipping should be done neatly and accurately. All sharp edges and burrs should be removed. Burred surfaces and flame cut materials should be ground smooth. Welding should be done neatly and effectively executed and should be free from all flaws and defects. Welding should be tested OK for porosity and cracks. Relevant welding tests to be carried out by DA. Bolt-holes should be accurately drilled and burrs should be removed. Washers and lock washers should be provided on bolts, studs and cap screws having straight threads. All bolts, nuts and screws should be correctly torqued. All bolts should have positive locking i.e. either Nylon lock nuts or spring washers with plain nuts should be used. All the steel parts will be zinc plated or hot dip galvanized as per IS-2629. All Aluminum parts will be hard anodized. Each part should be carefully chosen with due consideration to its weight since the vehicle is amphibious and the overall weight of the vehicle should be within stipulated limits. System wise weight budget will be given to DA which will have to be complied with. Any deviations to this to be approved from VRDE. Detail weight estimates of all aggregates will be forwarded to DA by VRDE within fifteen days from the DoM review meeting between VRDE and DA. Tolerance on steel thickness of +/- 10 % will be considered while estimating the weights.

(ii)

(iii)

(iv)

(v)

(vi) (vii)

Page: 24 of 31 (viii) VRDE reserves the right to incorporate changes/deviations of minor nature to the specifications and drawings in order to enable the prototypes to meet overall objectives. DA may suggest any deviation / improvement in the specifications and drawings which may be necessary during the development process. In the event of technical issues arising during the execution of said work contract, joint meeting between representatives of VRDE and DA will be convened to discuss the matter and arrive at an appropriate solution. Necessary technical waiver will be granted by the said committee on case to case basis and the work will be processed as per the decisions taken by the committee. DA will be bound by Committees decision. The committee will also be empowered to review the progress of the work by conduct of review meetings, stage inspections, take necessary course corrective actions to meet the project objectives. 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 design reviews will be conducted and necessary approvals will be communicated to DA by VRDE. All drawings, detailed circuit diagrams, data sheets of COTS and MOTS used items, sources, detailed document on software developed for embedded hardware with details on IDE platform shall be submitted after completion of task (1) The IPR in respect of overall concept and configuration of WHAP and its variants in the areas of survivability, protection and amphibious design will be with VRDE. (2) IPR for manufacturing, tooling, jigs and fixtures, assembly procedures will rest with DA. (3) Foreground IPR in respect of all new technologies / systems / subsystems / processes pertaining to this contract, inclusive of mutually finalized overall hull envelope of WHAP and its variants but excluding 1 and 2 above, will be held jointly by VRDE and DA.

(ix)

(x)

(xi)

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 during execution of task. VRDE team will be detailed to carry out the final inspection of the

Page: 25 of 31 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 Part II Part III contract : ATP of Bare Hull after 4 months of placement of contract : ATP of First Prototype after 13 months of placement of contract :ATP of Second Prototype after 23 months of placement of

4.9.1 Part I : ATP of Bare Hull 4.9.1.1 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

4.9.1.2 Blast 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

Page: 26 of 31 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) b) c) d) e) Blow Holes Cracks Incomplete welding (left out welding) Running of welding 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;

Page: 27 of 31 a) b) c) d) v) Lack of fusion Joint offset Incomplete penetration / fusion of root Lack of side wall fusion

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-automotive aggregates integrated in the vehicle will be measured as per assembly drawings provided by VRDE. Any deviation found needs to be rectified by DA. Testing of Electrical and Electronic systems:- Functional testing of complete Vetronics system for prototype I & prototype II will be carried out as per ATP. ATP document will be prepared by VRDE to carry out acceptance tests. Detailed ATP for Hull will be prepared by VRDE and forwarded to DA before assembly of automotive and non-automotive system Representative details of some of the tests mentioned are given below: Dimensional Checks
Sr. No. Parameter

ix)

x)

4.9.2.1

1 2 3 4

Overall length Overall width Overall height Distance from 1st Axle to 2nd Axle

Page: 28 of 31 5 6 7 8 9 10 11 12 13 14 15 Distance from 2nd Axle to 3rd Axle Distance from 3rd Axle to 4th Axle Angle of approach Angle of departure Minimum ground clearance Front Vehicle overhang Rear vehicle overhang Front track width Rear track width Ramp angle Wheel geometry

Weighment (Unladen)
Sr. No. 1 2 3 Parameter Front two Axles Rear two Axles 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 wheel 1 Position 2 Function of steering lock 1 2 3 4 Vehicle Dashboard Lower air pressure indicator and bipper High beam indicator Parking brake indicator Gauges

Page: 29 of 31 5 6 7 8 9 Speedometer with odometer Coolant temperature gauge Low oil pressure indicator Interlock test 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 pedal 1 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

Page: 30 of 31 designers trials 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 out by 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 2 3 4. 5 Steering position Steering effort/movement/wobbling Steering operation on both sides Steering wheel self-centering ISO tests for transient stability and handling maneuvers

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

Page: 31 of 31