Technical Specification Articulated Aircraft Refueller (11-12 KL Capacity) ` Qty: 6 Units ` SN CRITERIA REQUIREMENT Offered specification

1.

General Aircraft Refueller (11-12 KL) suitable for delivery of Aviation fuel grade Jet A-1 to aircraft. It should be designed for delivering the fuel into the aircraft through reelhoses by underwing refueling. It shall also be capable of defuelling aircrafts as specified elsewhere in the document. National and International practices, norms and standards shall be followed for the safety measures in design and fabrication of the Refueller.

Make: Model: Country of origin:

2 A. TRUCK

a.

General Rigid Truck, 4x2 drive, Right Hand Drive for the required Aircraft Refueller and suitable for operating

C and altitude of 2000 m.

Make: Model: Country of origin:

b.

Engine Water cooled, Diesel engine developing adequate rated net flywheel horse power not less than 160 hp at the governed speed (engine fully equipped with accessories) for efficient full load operation at operating conditions as stated in the bid documents. Engine to be provided with cold starting device, heavy duty air cleaner, direct electric starting system, heavy duty batteries and fuel tank with water collection chamber and drain tap. Exhaust pipe of engine to be routed so that it is on the passenger side of the vehicle. This is to be fitted with a perforated mesh shield. Spark arrestor to be fitted so that there is no ignition due to the exhaust causing any explosion. Fire screen shall be provided at the back side of the cabin. Fire screen shall extend upto 300mm from ground level and shall be made by sandwiching asbestos sheet between two steel sheets and should be sturdy and fitted firmly. Fuel tank shall be located on passenger side of chassis and all flexible fuel lines in engine fuel system must be armour braided externally. The air induction system shall be relocated, if required, and/or protected so as to minimize the possibility of induction of fuel from any spillage of flammable liquid, from any release of liquid from a safety relief device or breather valve on the cargo tank, from any release of liquid from the aircraft being serviced (e.g. from wing tip vents or from refuel/defuel receptacles) or from ruptured hoses. Emergency engine stop shall be fitted, operable from the front and rear of the dispenser.

c.

Gauges To include hour meter, odometer, engine temperature, engine oil pressure, fuel, charge indicator, hydraulic gauges necessary for efficient operation and maintenance of the Refueller.

in conditions -5° C to 50°

SN CRITERIA REQUIREMENT Offered specification

d.

Axles Front: Heavy duty Reverse Elliot ‘I’ beam section or suitable section to support the load at front axle. Rear: Fully floating hypoid gear

e. Suspension Semi Elliptical leaf springs at front with shock absorbers,

Semi Elliptical leaf springs on rear or equally suitable type.

f. Transmission Heavy duty disc type clutch, heavy duty 5 forward and 1 reverse speed gear box.

g. Steering Hydraulic Power assisted.

h. Brakes Air or Air Over Hydraulic service brake on all wheels with

fail proof safety device, engine exhaust brake. Independent parking brakes required.

i. Tyres 10.00x20, 16 PR, tube type or suitable size

j.

Cabin Fully enclosed pressed steel cabin with laminated glass windscreen, intermittent wiper, locking service doors, cushioned and adjustable driver’s seat, cushioned seat/seats for co-drivers. Two sunvisors, floor mats, rear view mirrors on door shall be provided.

k.

Electrical System

24 Volt systems. Wiring passing through suitable conduits for the electrical system of chassis shall be provided. It should be in accordance with the anti-explosive norms and standards. The battery box shall have minimum insulation thickness of 4 mm. A battery isolation switch shall be provided and a battery boost socket also be fitted adjacent to it with clear marks and symbols.

l.

Essential Accessories

Road lights, emergency lights, cabin lights, Refueller operating lights. A transistorized amber flashing light with an output of minimum 40 and max. 400 candles and a flash rate between 60 and 90 flashes per minute shall be fitted centrally on the cab roof, to be visible through 360 degree in the horizontal plane. This light should be operated from the cab. One universal joint type spot light for night operations. Three Airfield obstruction lights Three reflectors at the rear and the sides One interlock warning flash light inside driver’s cab One PTO indicator light inside driver’s cab. One Spare wheel with tyre-tube. Tool kit in a lockable tool box.

3 C. TANK , DISPENSING UNIT AND FITTINGS Make:

Model: Country of origin:

a

General It shall be designed for net/usable carrying capacity plus minimum 5% ullage for vapour space, of its net carrying capacity. The tank shall be fabricated with Mild steel (conforming to specifications IS 5986, grade Fe 410 or equivalent) with epi-coating over sand blast surface finish. Stiffening of the tank shall be done externally. The tank shall be mounted firmly on the chassis firmly providing suitable rubber packing in between tank and the

43

SN CRITERIA REQUIREMENT Offered specificationchassis wherever applicable. The tank shall be tested by hydro static pressure of not less than 0.316 kg/cm2 for a period of not less than 1 hour. The tank should have proper gutters so that the rain water does not run down the side. A non slip flat walk way should be provided on the top of the tank. The walk way should cover the entire enclosed portion at the tank top and should be removable for proper cleaning of the tank top. The walk way should cover the entire tank top and should be grating type so that the Refueller tank top is visible always. The grating should be removable so that the tank top can be painted/repaired at a later stage as required.

b Capacity Tank capacity approx. 12000 liters with 3 interconnected

compartments, each compartment not to exceed 5000 liters. With a 10” tank content gauge facility.

c Manholes Manholes shall be positioned such that they provide a line of sight to the low point sump wherever applicable.

d

Suction The tanks should have provision and procedures for systematic draining of tank bottoms (water and sediments).

e

Fuel Pipe Circuit The piping system and all components upstream of the meter and including the meter shall be able to withstand a minimum working pressure of 150 psi (10 bar). Pipe work & components downstream of the meter to be designed to accept a hydrostatic test of minimum 300 psi (20 bar). It shall be protected by a thermal pressure relief system.

f

Pressure and Surge Control

Refueller shall be fitted with pressure control systems to protect air craft from excessive flow and shock pressures (surge) which can damage aircraft. One combined in-line pressure control/deadman shut-off valve operating at the same time as non return valve with adjustable pressure regulator and deadman pilot valve shall be installed down stream of the pump, consisting of:2 venturi with shuttle valve, 1 rated for the deck hoses and one rated for the reel hoses. 1 deadman switch, actuating the pneumatic deadman control unit. 1 pneumatic deadman control unit. 1 manually operated deadman override valve. Fluid Transfer (UK), Gammon (USA), ALFONS HAAR make Deadman control system complete with hand switch, solenoid, timer, light indicator and buzzer for indicating the fuel flow/level with minimum 14 mtr coiled cable. It should close within 5 secs and open within 10 secs approximately.

g

Dispensing Unit The fuel dispensing unit shall be mounted at the suitable location of the trailer considering all the safety norms and standard for aviation fuels. It will be designed for delivering the fuel into the aircraft through two reelhoses or two deckhoses by underwing refuelling. The unit shall also be capable of defuelling aircrafts for load adjustments.

h Discharge Capacity

Flowrate through deckhoses 2500 LPM (approx.) Flowrate through hose reels 1500 LPM (approx.)

SN CRITERIA REQUIREMENT Offered specification

i

Metering Liquid Control/ISOIL/Avery Hardoll make, positive displacement meter with mechanical counter having roller type counter will be fitted with 5-digit numerator, zeroable and with 7 digit totalizer and flow rate indicator. Ticket printer and flow rate indicator shall be fitted. Calibration: Decalitre, but every 1 litre readable. The meter should be suitable for flow rate: 3000 L/min (approx.).

j

Filtration Velcon/Facet/Faudi make filter water separator meeting latest API specification. Flow rate: min 2500 L/min. Operating pressure: 10 bar Material: Epoxy coated steel construction. Following equipment are required for the filter: Piston differential pressure gauge to be mounted on control panel. Appolo or equivalent make Water sump with drain valve spring return 25.40mm ball valve and dust cap in stainless steel. 1 automatic air eliminator 1 gas return line to the tank 2 millipore test connections on inlet and outlet of the filter.1 pressure safety valve shall be fitted. 1. Sampler of approx4 ltr capacity for taking samples of inlet and outlet of filter fitted with Apollo or equivalent spring return ball valves.

k

Hosereel system (Underwing Refuelling)

2 ball valves of suitable size for flow control 2 drum hosereel of suitable size for hose winding with hydraulic power rewind, Hosereel of standard design, hydraulic control valves. 2 antistatic aviation fuel hoses, 50mm x 18.30 m according to BS 3158/85 C2 or equivalent fitted with aviation fuelling standard Elaflex/Hewitt/Trellelborg make hose end fittings. 2 under wing pressure fuelling nozzles make Carter 64348 CDEF46K-45psi or equivalent 2 supports for the fuelling nozzles. 2 sets of hose guide rollers of aluminum.

l

Deck Hose system

2 ball valves of suitable size for flow control 2 swivel joints of suitable size 2 antistatic aviation fuelling hoses of minimum 63.50 mm x 3.00 m size, according to BS 3158/85 C2 or equivalent fitted with aviation fuelling standard Elaflex/Hewitt/Trellelborg make hose end fittings. 2 underwing pressure fuelling nozzles. 2 supports for the fuelling nozzles. For circulation of fuel from Deck Hoses following arrangement to be provided.

i. 63.50 mm international standard 3 Lug Adaptor – 2nos.

ii. 80.00 Butter fly valve – 2 nos. iii. 80.00 Pipe line -2 nos.

m

Hydraulic drive of hosereels

Hosereels shall be driven by high torque hydraulic motors. Proper attachments and accessories shall be provided with separate controls for the hosereels with adjustable limitation and speed adjustment with 3 positions "Rewind, Stop and Unwind", overrun brakes for the hosereels also provided.

SN CRITERIA REQUIREMENT Offered specification

n Defuelling equipment

The Refueller shall have proper arrangement for defuelling the aircraft keeping all the safety measures.

o

Instrument and Controls

All instruments and controls associated with the fuelling operations shall be grouped on the left hand side on a control station inside the pump compartment and properly labeled in English which will include: Engine Throttle control Hose control valves for refuelling and defuelling Hose rewind controls Meter head and rate of flow indicator Tank foot valve controls Engine emergency stop Product temperature gauge

p

Instrument panel The panel will include the following: Venturi pressure gauge Pump speed indicator Pump vacuum gauge Pump pressure gauge Hydraulic pressure gauge Air pressure gauge Master gauge testing point, connected to the delivery side of the pump. Piston type differential gauge All pressure gauges shall be glycerin filled and calibrated in psi and kp/cm2 Flow diagram Operating instructions Electric circuit

q

Location of Refuelleing equipment and accessories

Refueling equipment like filter, Hose reels etc to be installed at suitable location of the tank.

r

Bottom Loading Bottom loading arrangement shall consists of i. Carter/Whittaker make minimum 100.00 mm

Tank Bottom Loading Valve (internal valve) ii. Carter/Whittaker make Jet Sensor to shut off

tank Bottom Loading Valve when tank is filled upto required level.

iii. Pre-check valve iv. 1 No 63.50 mm international standard 3 Lug

Adaptor with 80.00 mm Butterfly valve on each side of the Tank

s

Main Pump A centrifugal pump of suitable discharge capacity to meet the fuelling should be driven by the truck engine through an efficient drive system.

4

a

Safety Equipment

Interlock: 1.) Mechanical PTO interlock to prevent engagement of road gear when PTO is engaged. 2.) Hydraulic/Pneumatic/Electrical interlock system to prevent the Refueller from driving when: (i) Reel hoses are not properly stowed (ii) Deck hoses are not properly stowed (iii) Hose unit is connected Interlock override system in driver’s cab shall be installed,

SN CRITERIA REQUIREMENT Offered specificationeasily accessible from driver’s seat with warning light. Engine emergency stop: Two emergency engine stops, clearly marked, one shall be fitted in driver’s cab and another on the instrument panel located at dispensing unit.

b

Fire Protection Two open topped scabbard to house 10 kgs dry powder fire extinguishers, one on each side of the vehicle shall be installed and one 1 kg dry powder extinguisher to be installed in the cab.

c Towing Facilities for towing shall be provided at the front and

rear of the vehicle to permit moving in case of vehicle failure.

5

Manuals 1. One copy of the Operator's and Owner's Instructions and Maintenance manual in English shall be supplied with each equipment (separately for Truck, Tank and Dispensing Unit). 2.Two copies of following manuals in English shall be supplied: a) Spare parts catalogue for Truck, Dispensing Unit and other accessories. b) Workshop manual for Truck, Dispensing Unit and other accessories.

6

Proven performance

1.The major equipment (Truck, Dispensing unit and its accessories) offered shall be a current model under standard production by the manufacturer for at least one year. 2. The bidder shall provide the manufacturer's data of the performance of the unit to include the fuel consumption, performance curve of the engine and production capacity of the Tractor Head.

7

Spare parts Supplier shall provide the manufacturer’s recommended ex-works price of spare parts for one unit of Refueller for future reference. Recommended spare parts list in the following manner i. For 500 Hour operation of the Refueller ii. For 1000 Hour operation of the Refueller iii. For 10000 Hour operation of the Refueller

8 Warranty Manufacturer shall provide a minimum of one year warranty after acceptance.

9

Initial Service The supplier shall provide with the equipment all the necessary filters and spare parts required for the first two servicing, after the Refueller has been commissioned and accepted.

SPARE PARTS APPENDIX SPARE PARTS FOR Air Craft Refueller

S. N. Description Part No. Unit CIP Site Unit Price

CIP Site Unit Price

Quantity Amount

In Fig In Words Reqd. Engine group 1 Fuel Filter Element Sets 30 2 Oil Filter Element Sets 30 3 Air Cleaner Element Sets 12 4 Glow plug/Heater plug Sets 6 5 Fan belt Sets 12 Fuel pump Sets 6 Plunger barrel assembly Sets 6 7 Delivery valve Sets 6 8 Injection nozzle tip Sets 6 9 Dispensing Unit Group 10 Filter Cartridges for Filter and

Water separator unit Sets 30

Spout Kit (for refueling nozzle) Sets 12 11 Strainer assembly (for refueling

nozzle) Sets 12

12 Valve seal kit (for refueling nozzle)

Sets 12

Total

Total EXW Price: