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RRCAT/IMA/RSS/2013 Date: 16/09/2013
High precision machining and supply of accelerator components
1.0 Scope of work
This document lists technical requirements for high precision machining and supply of accelerator components.
The scope of work includes OFE copper rods procurement, machining, inspection, packing and supply of accelerator components to RRCAT, Indore.
Bidders shall quote for complete set and not for individual components in view of the strict repeatability requirements. The offers will be evaluated on the basis of cost of one set of components in view of the quality control requirements. Considering the development aspect involved in this work and repeatability of process parameters to achieve repeatable and interchangeable components, the order will not be split on different bidders.
2.0 Bidders qualification criteria
Only those bidders are qualified to bid who fulfill following conditions. Full information on the following points shall be provided in the bids.
2.1 These high precision components are to be indigenously developed hence bids from bidders who can machine these components in India only will be accepted. Bids from traders will not be accepted.
2.2 Bidder shall be ISO 9001 certified or its equivalent National/International certification for the manufacture and supply of high precision components.
2.3 Bidder shall have below mentioned machining and inspection facilities. The minimum specs of these shall be as follows: a) Ultra precision CNC lathe having aerostatic bearing and hydrostatic slides -
Position accuracy < 0.05 micron, Spindle run out < 0.1 m , or a machine of equivalent technology capable of meeting dimensional and surface requirements specified on the drawings,
b) CNC Lathe/ Turn mill center - Position accuracy < 3 micron, c) VMC / HMC used for coupler machining - Position accuracy < 5 micron, d) CMM (with graphical report generation capability) - volumetric accuracy < 1 microns
over 300 mm length, e) Surface finish tester - Resolution < 0.05 micron (Ra).
These machines shall be kept in temperature controlled facility. 2.4 Bidder shall submit size and accuracy specifications of CNC machines, coordinate measuring
machine (CMM) and other tools and instruments which they propose to use along with the bid. The details of the above machines and their location may be verified by RRCAT at the bid evaluation stage. If sizes/accuracies/machine specifications do not meet the requirements of the job, bid will be rejected.
2.5 Ultra precision CNC lathe & all the measuring facilities shall be housed in Class 10000 clean room with a temperature control better than 1C to ensure precision and reliability. The set temperature of the facility shall be informed in the bid and the set temperature shall not change during the execution of the order.

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2.6 Bidder shall give details in their bid as to how they propose to achieve dimensional tolerances better than 3 microns and surface finish better than 0.1 microns Ra. The details shall include selection of machines, processes, parameters, dust control, temperature control, etc.
2.7 Bidder should have completed precision machining jobs involving dimensional tolerances of 3 microns and surface finish better than 0.1 microns Ra. Bidder shall give full contact details and contact address of customers to whom he has supplied these components. RRCAT may verify the details with these parties.
2.8 If bidder is subcontracting any operation related to this tender, he shall provide full details of the sub-contractor, address and specifications of the machines to be used, QA system of sub-contractor and his approval procedure for the subcontractor. The bidder shall have a written agreement with sub-contractor to use the mentioned facilities for this contract (To be attached with the bid).
2.9 Bidder shall machine a test job as per drawing No. RRCAT/IMA/MML/71/R0 on the machine proposed to carry out this work and submit it along with inspection report for machining qualification during bid evaluation using suppliers own material. In case bidder cannot arrange the material, RRCAT representative will carry the RRCAT material to the machining facility of the bidder. He shall machine the test job, carry out the inspection and handover the machined job and inspection report to the representative for further evaluation of the bid within 3 days. Since the evaluation of the offer will be based on the above points, the bidder is encouraged to provide maximum details on the above requirements. Not giving specific and parametric reply to the above points may lead to rejection of offer.
3.0 Bid evaluation process
The offers will be evaluated on the basis of following:
3.1 Detailed technical information by the bidder as asked in Bidders qualification criteria.
3.2 Submission of test job and its inspection report. Failure to submit the test job will DISQUALIFY the offer.
3.3 Prompt response to the technical queries raised by the purchaser. In case response is not received against technical query within five working days, the offer will be treated as rejected on technical ground.
3.4 The bidder must give a presentation about their capability to machine high precision accelerator components. Failure to make the presentation will DISQUALIFY the bidder. Technical presentation shall be made by bidders representative who can respond to queries on the floor.
3.5 The purchaser reserves the right to visit the bidders facility for evaluation prior to finalization of the order.
4.0 Conditions
Two part public tender procedure comprising of two separate bids as given below, shall be followed.
a) Part I (Techno-Commercial) bid
b) Part II (Price) bid
The bidder is required to submit bids in accordance with DAE-DPS guidelines (Two Part Tender (TPT) of http://www.dpsdae.gov.in/DOC/chapters.pdf). Please see http://www.dpsdae.gov.in/bid documents for details.

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4.1 Documents to be submitted with Part I (Techno-Commercial) bid
The bidder is required to submit following documents with the Part I (Techno-Commercial) bid. Failing which his offer is liable to be ignored.
a. Point wise information asked in bidders qualification criteria,
b. Point wise confirmation of these specifications,
c. Mandatory questionnaire duly filled in,
d. Details of sub-contracted work/systems and technical details of proposed sub-contractors.
e. Deviations, if any, from these specifications.
4.2 Technical discussions and presentation of offers
Bidder can seek clarification/ discuss technical requirements of machining through an enquiry to purchase department (IRPU, DPS, RRCAT, Indore-452013).
The Bidder shall make a formal presentation of his Part I (Techno-Commercial) bid at RRCAT, Indore during bid evaluation stage. He shall do so within a week of notification.
5.0 Technical requirements
5.1 Manufacturing drawing
Drawings applicable for machining and inspection of the components are mentioned in Table-1.
Table-1
S.No. Drawing No. Title
1. RRCAT/IMA/MML/040/R0 sh 1 of 1 Accelerating structure assembly
2. RRCAT/IMA/MML/037/R0 sh 1 of 5 Input coupler end group
7. RRCAT/IMA/MML/039/R0 sh 1 of 1 Cells stack sub assembly
8. RRCAT/IMA/MML/004/R0 sh 1 of 1 Buncher cell Type -2B
9. RRCAT/IMA/MML/005/R0 sh 1 of 1 Buncher cell Type -2A
10. RRCAT/IMA/MML/006/R0 sh 1 of 1 Regular cell - A
11. RRCAT/IMA/MML/007/R0 sh 1 of 1 Regular cell - B
12. RRCAT/IMA/MML/038/R0 sh 1 of 3 Output coupler end group
15. RRCAT/IMA/MML/041/R0 sh 1 of 1 Ring nut
16. RRCAT/IMA/MML/71/R0 sh 1 of 1 Test job for machining qualification

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The dimensions specified on drawing are at 30C. Suitable temperature control shall be maintained during machining and inspection of the components since the temperature change will lead to change in dimensions. The coefficient of thermal expansion of copper is 17 m/m.K. In case machining or dimensional inspection is done at temperature different from 30C, suitable temperature compensation shall be used.
5.2 Material
The material of components is given on manufacturing drawings. The accelerator components are to be machined from oxygen free electronic copper rods of grade 1, UNS No. C10100 as per ASTM F68 and ASTM B187. The flanges are to be machined from austenite stainless steel grade 316L as per ASTM A240.
Bidder shall submit mill certificate / inspection certificate 3.1 as per EN 10204 for chemical analysis and mechanical properties to RRCAT for acceptance. RRCAT may ask copies of invoice and communicate with the original material manufacturer to ascertain its quality and genuineness. RRCAT may carry out additional testing for chemical analysis and mechanical properties at a NABL approved lab, at its cost to verify the certificates.
The manufacturer of OFE copper rods and stainless steel grade 316L for this work shall be ISO 9001 certified with production of extruded, drawn and rolled products in its scope. Material acceptance