23-40-1001 SAM SOW.pdf

VIBB 23-40-1001

PURCHASE DESCRIPTION FOR THE ACQUISITION OF A

HEAT TREAT FURNACE

SCOPE.

Scope. The content of this specification describes the minimum requirements for the design, operation, construction, installation to building 3001 Tinker AFB, Oklahoma, and acceptance procedures for a vertical loading vacuum furnace, gas quench system and accessories described herein. The Furnace will be used to perform various heat-treating processes including Nickel and Copper brazing.

APPLICABLE DOCUMENTS. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they shall meet all requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed in section 2.

Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

Government Documents.

Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein.

STANDARDS – FEDERAL

FED-STD-H28B: Screw Thread Standards for Federal Service

FED-STD-313F: Material Safety Data, Transportation Data, and Disposal Data for Hazardous Materials Furnished to Government Activities

U.S Department of Labor, Occupational Safety and Health Administration

(OSHA)

29 CFR 1910: General Industry, OSHA Safety and Health Standards

(Application for copies should be addressed to the OSHA Publications Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257- 0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx) https://quicksearch.dla.mil/qsSearch.aspx

Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

American National Standards Institute, Inc. (ANSI)

ANSI/NEMA-FB 1 Fittings, Cast Metal Boxes, and Conduit

Bodies for Conduit and Cable Assemblies

B11/STD B11 General Safety Requirements Common to ANSI B11 Machines

(Applications for copies should be directed to the American National Standards Institute, 1300 North 17th Street: Suite 1752 Rosslyn, VA, 22209 Phone: (703)841-3200/3258)

AMERICAN SOCITY OF MECHANICAL ENGINEERS (AMSE)

ASME BPVC-VIII- Rules for Construction of Pressure Vessels Division I

Applications for copies should be directed to ASME International, Three Park Avenue, M/S 10E, New York, NY 10016-5990.)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum)

NEMA MG 1: Motors and Generators

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code

NFPA 79: Electrical Standard for Industrial Machinery

NFPA 86: Standard for Ovens and Furnaces

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

Society of Automotive Engineers (SAE)

SAE AEROSPACE MATERIAL SPECIFICATION (AMS) 2750: (R) Pyrometry

(Application for copies should be addressed to: Society of Automotive Engineers 400 Commonwealth Drive, Warrendale PA 15096)

American Society for Testing and Materials (ASTM)

ASTM E 380-91: Standard Practices for Use of The International Systems of Units (SI) (The Modernized Metric System)

ASTM SI 10: American National Standard for use of the International System of International System of Units (SI) The modern Metric System

ASTM D3951: Standard Practice for Commercial Packaging

Applications for copies should be directed to the American Society for Testing and Materials 1916 Race St., Philadelphia, PA 19103.

International Organization for Standardization (ISO)

ISO 4414: Pneumatic power General rules and safety requirements for systems and their components

ISO 2861: Vacuum technology Dimensions of clamped-type quick-release couplings

Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

2.4 Acronym Definitions Not Explicitly Listed in Text. The following acronyms not explicitly listed in each section text are defined as follows:

a. JIS- Japanese Industrial Standards

b. DIN- German Institute for Standardization

c. EN- European Standard

REQUIREMENTS.

Design. The items offered shall be new and a current, commercially available model.

Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The system design and construction shall include all parts, components, and features necessary to provide high temperature, required air capability, and be as energy efficient as modern construction methods allow.

The furnaces systems shall be complete so that when installed and connected to the specified utility sources it can be used for all operations for which it was designed as designated in this specification. Materials exposed to the internal environment of the furnace chambers shall be compatible with the type of atmosphere and temperature conditions specified for the furnace. The furnaces shall be designed to load parts into the heat-treating chamber vertically. Construction shall be free from any characteristic or defect that will prevent the furnaces from passing any of the examinations and tests specified herein.

Measuring and Indicating Device Graduations. All process parameters shall be displayed in the English system or units (degrees Fahrenheit, etc.), in accordance with ASTM E 380-91 and ASTM SI 10. Non process specific parameters, such as cooling water temperature gages and pressure gages, may be displayed in standard units of psig or degrees Fahrenheit.

Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's work station(s).

Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910 or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI

B11 equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

3.1.3.2 Safety Devices. The system shall be equipped with all safety devices required by 29 CFR 1910 and NFPA-86 AMD 1. These shall include but are not limited to:

1.Limit switches on automatic movements

2.Breaker-equipped electrical cabinets

3.Red emergency stop button

a. The emergency stop button shall immediately shut down all electrical current to furnace heating elements. All other systems shall remain in operation. The emergency stop button shall require an active reset on the part of the operator to resume operation. No automatic resets are permitted.

b. The system shall be set up that in the event of a water failure of any kind the diffusion pump and heat contractor are automatically shut off and a manual restart is required. The machine shall notify the operator of a water failure, should it occur.

c. The system shall be equipped with a main breaker which shall disconnect all electrical flow to the system. Additional breakers shall be provided to disconnect electrical flow to individual heating zone elements.

3.1.3.3 Equipment Protection. Short circuit protection shall be provided for auxiliary controls, instruments, relays, and sensing devices, etc. All electric motors of ¼ horsepower and larger shall be provided with short circuit and thermal trip overload protection. Motor sizes shall be such that driven load will not exceed the continuous duty rating of the motor with a maximum load in the chamber. Solid state reduced voltage (soft start) motor starters shall be provided for polyphase motors 25 horsepower or larger.

Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. These materials shall not be brought on site without prior approval of the Government. Radioactive materials or instruments capable of producing ionizing radiation as well as materials which contain asbestos, mercury, lithium, methylene chloride, lead (= or >0.06%), or polychlorinated biphenyls (PCB’s) are prohibited. Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313F.

Nickel Metal Hydride and lithium batteries are permissible for memory backup. Class I Ozone Depleting Substances as defined in 40 CFR 82 shall not be used in the performance of this contract, or be provided as part of the equipment. Exceptions to the prohibition of these materials shall be referred to the Contracting Officer in writing, for consideration, not later than 60 calendar days after effective date of contract and prior to any work being performed.

Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by federal, stale, or local statutes in effect at the point of installation.

Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts. Recirculating systems shall include filters, which are cleanable and/or replaceable.

Each lubricant reservoir shall have visible or mechanical means for determining fluid level.

All oil holes, grease fittings, and filler caps shall be accessible. Parts consuming fluids shall be clearly identified as such, along with the recommended periods of additions and the specific fluids required for functional system operation over the life of the machine.

Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

Foreign-sourced replacement parts shall either be interchangeable with domestically supplied components or be readily available from a domestic source.

Construction. The machine shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder or paste shall be used for reclaiming any defective part.

Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed. All such parts that are subject to removal or adjustment shall not be swaged, peened, staked, or otherwise permanently deformed.

Threads. All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Gears. All gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel.

Surfaces. All surfaces shall be clean and free of harmful or extraneous materials.

External surface edges shall be rounded or beveled unless sharpness is required to perform a necessary function. Except as otherwise specified herein, the condition and finish of all surfaces shall be commensurate with the manufacturer’s standard commercial practice.

Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

Painting. The machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead free type.

Workmanship. Workmanship of the machine shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

Components. The machine shall consist of not less than the following components:

Base. The base shall be a stress relieved, heavy duty, ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling.

Vacuum Pumping System. The furnaces shall be provided with an automatically operated vacuum system. The system shall consist of all pumps, manifolds, valves, traps, controls, gauges, and piping to meet the requirements. The system shall be provided with a pneumatically actuated high vacuum valve that will automatically close in case of power failure. The system shall be provided with dust traps or filters to prevent dust and particles from entering the systems pumps.

Vacuum/Pressure. The furnace shall be preconditioned to ensure the following performance can be met.

a. Cold. The furnace shall produce a minimum operating vacuum of 5 x 10- 5 torr in 30 minutes or less when in a clean, dry, and empty condition.

The leak-up rate or pressure rise shall not exceed 5 x 10-3 torr per hour when under clean, no-load conditions.

b. Hot 1. The furnace shall produce a minimum operating vacuum of 5 x

10-5 torr in 30 minutes or less when in a clean, dry room temperature and empty condition. It shall be able to heat up to 2300 F and vacuum cool to 2100 F and with the power to the hot zone "on" the leak-up rate shall not exceed l0x 10-3 torr per hour.

c. Partial Pressure. The furnace systems shall be able to operate in a controlled partial argon pressure condition of 1000 microns maximum.

Vacuum Valves. The furnace vacuum systems shall have all the valves integrated into a system, which shall be able to function either in an automatic or manual mode. The manual operation of the vacuum system shall require the insertion of a key (or optional password protected "soft" key) with the following pumps.

Mechanical Roughing Pump and Booster Pump. A Stokes 412 with 615 booster or equivalent shall be provided. The pumps shall meet the vacuum requirements in section 3.3.2.1. The pumps shall be put in series and shall be equipped with an oil mist separator and roof vent exhaust connections. These pumps shall be mounted in a "drip pan". All belt covers shall be slotted, or air vented to reduce excessive heat and provide a visual indication of belt wear or failure. The contractor shall install the exhaust lines from the pumping systems through the provided roof penetrations (at approximately 24 feet high). The exhaust stacks shall be adequately secured and include rain caps or equivalent to minimize intrusion of rain.

Diffusion Pump. A 35-inch diameter Agilent Varian high-speed vacuum oil diffusion pump shall be provided to meet vacuum requirements in Section

3.3.2.1 The pump shall have a dual set point heating control system. The pump shall be properly interlocked with the furnace to prevent furnace operation until the pump is at a running condition. The contractor shall provide a heater for diffusion pump oil, a sight level gauge to determine level of diffusion pump oil and the required amount of vacuum oil as required for this diffusion pump to operate safely and effectively.

Mechanical Holding Pump. The mechanical holding pump shall be sized to meet the vacuum requirements in Section 3.3.2.1 and equipped with an oil mist separator and roof vent exhaust connection. This pump shall be mounted in a "drip pan".

Foreline Vacuum Indication. The foreline pressure and the holding pump system pressure shall be continuously monitored by vacuum gauges (pirani) and indicated on a vacuum meter on the control panel. A manual selector switch shall allow one or the other vacuum gauge inputs to be indicated on the meter (or indicated on the optional CRT MMI).

Vacuum Chamber. The machine shall be provided with a Vacuum chamber that meets but not limited to the following requirements:

Vacuum Chamber Construction. The furnace chambers shall be water-cooled, and the outer furnace surface temperature shall not be higher than 10 degrees Fahrenheit from ambient. The water jacket shall have a drain valve(s) and shall be designed to prevent corrosion. The water jacket or space between the inner and outer shell may be divided into a suitable number of cooling zones with the baffles to provide uniform surface chamber temperature. The vertical vacuum chamber shall be heavy, double walled steel to perform full water-cooling including the door and rear section. The basic chamber and door shall be designed and fabricated in accordance with ASME BPVC-VIII standards. Formal certification shall be required. The inner shell and all structural material exposed to the vacuum environment shall be constructed of material that will not oxidize or shall be constructed of materials that have been plated or coated to prevent oxidation under all furnace operating temperatures, atmosphere, and vacuum pressures specified herein.

Vacuum Chamber Cooling Water Lines. All exit cooling water lines from the furnace shall be positively identified as to their furnace source at the point where they empty (converge) into a return collector or manifold. The cooling water connections shall be standard pipe connections (a minimum of 2-inch nominal diameter) to accept conditioned water from the building cooling water supply system. All fittings shall be stainless steel or copper. All exit cooling water lines shall include visual in-line flow indicators and shall be manifolded for a single point return connection to the Governments closed-loop water system.

Water Cooling System for Bldg. 3001. The contractor shall connect the furnace to the existing evaporative closed-loop cooling system. A pneumatic control valve shall be provided to regulate water pressure down to the required range. The contractor shall provide all valves, fittings, piping, gages, and insulation for both the cooling water supply and return lines. The cooling water supply and gravity return lines are located within 25 feet of the furnace locations. The contractor shall cross-connect the furnace cooling water supply and return lines with each buildings potable water system for emergency cooling. The connections shall be made such that in the event the primary cooling water system goes off-line the operator can "shut-off” the water from the cooling water system and "turn-on" the water from the potable water system to prevent damage to the system.

Furnace Cooling Water Filters. The contractor shall provide and install dual inlet water screen filter system for the furnace. The filters shall be in parallel and include the necessary valves and piping to clean either screen/filter without shutting off the water. The filter/screens shall be of 0.060-inch minimum mesh stainless steel screening.

Furnace Chamber Ports. The vacuum chamber shall contain all required ports for the high vacuum pumping system, gas quench system, power terminal entries and furnace over temperature, control thermocouples, and resident system accuracy test thermocouples in accordance with ISO 2861. These requirements are further specified as follows:

a. The furnace control thermocouple, resident system accuracy test thermocouple, and the over-temperature thermocouple shall be in separate ports with vacuum-tight glands and adequate extension wire to the control cabinet. Review sections 3.3.17 and 3.3.6.2 for additional survey/calibration thermocouple port requirements.

b. The vacuum furnace shall have a separate inlet port (penetration of the furnace wall) for argon gas quenching. The gas line shall have a solenoid actuated vacuum valve.

c. All instrument or sensor connections on the vacuum chamber shall have Klein Flansche Type vacuum fittings or equivalent.

d. The vacuum chamber shall have three additional ISO Klein Flansche vacuum ports accessible at ground leve1. Two of these ports will be 1 inch ISO NW 25 flange size with sealed/blank-off ends for possible future use. The remaining Klein Flansche port will support connection of a Residual Gas Analyzer (RGA) and shall include any Klein

Flansche type fittings necessary to support intermittent connection of same.

Vacuum Chamber Door. The furnace shall be vertically loaded and shall provide complete access for loading/unloading of the hot zone, hearth, and fully loaded. The door shall have powered door clamps. The door shall be pneumatically operated, with a positive pressure closure for positive pressure quenching and to ensure safety and ease of opening. A standard autoclave door sealing ring with contacts to the door at a minimum of 24 inches center to center spacing of contacts around the circumference of the door shall seal the vacuum chamber door. The door will pneumatically lock automatically upon contact with the chamber. The ring shall rotate to seal. Contractor may propose an alternate door locking design. Drawings of the design and customer references shall be provided with the proposal.

Hot Zone requirements.

Workload Size. The work charge volume or hot zone shall be no less than

72 inches in diameter and 72 inches high. The qualified work zone shall not exceed the work charge volume or hot zone. The hot zone shall be constructed to permit gas cooling as specified in paragraphs 3.3.5.1 and 3.3.5.2.

Furnace Hearth Support and Grid. The furnace hearth support shall be include one work grid. The hearth shall provide a stable flat support for an evenly distributed load of at least 2000 pounds at 2300 degrees Fahrenheit without permanent distortion.

Heating Elements. The heating elements shall be arranged radially around the circumference of the work zone in not less than two individual control zones and shall comprise approximately 50 percent of the furnace work length surface area. Each zone shall include all power trimming devices to provide a user-friendly means of linearizing the power distribution to each zone for temperature uniformity. The element to furnace wall attachment design shall be of high integrity fasteners that are easily removed for servicing and replacement but are not fragile or weak as to cause premature failure of the elements. The insulation and heating elements shall be arranged to minimize heat loss and assure temperature uniformity and heating requirements specified herein.

Insulation Package. The hot zone insulation package shall be housed in stainless steel gas distribution plenum/ hot zone structure.

Gas Quench System: Orbital Type. The machine shall have a gas quench system of the orbital type with not less than the following requirements.

Gas Quench System. The furnace gas quench system shall be provided with the capacity and all equipment for the machine to quench at a minimum of 2 BAR to the furnace workload. The quench system shall be a closed loop, recirculating argon gas cooling system complete with a silent turbine type blower and motor of 100 horsepower minimum, heat exchanger, and internal distribution nozzles for fast, uniform 360 degree cooling of the workload. The heat exchanger shall be sized to support the cooling rates defined in Section 3.3.25.C.

Gas Quench System Configuration. The blower and heat exchanger units may be internally or externally mounted. In the event the blower and heat exchanger are internally mounted, contractor shall demonstrate provisions to prevent cooling water leakage from entering the furnace chamber. The contractor shall provide information on potential points of failure of internally mounted blowers and heat exchangers, and how to prevent and mitigate such occurrences.

Gas Quench Control. An automatically actuated gas damper valve(s) shall be provided on the gas inlet to modify the flow of quench gas into the hot zone and provide for programmed cooling rate control.

Hygrometer/Dew Point Recorder. The furnace shall be equipped with a hygrometer to determine the dew point of argon entering the furnace. Dew point shall be displayed on the control cabinet in degrees Fahrenheit. The hygrometer shall be calibratable by Tinker PMEL.

Thermocouples.

Thermocouple Extension Wire and Connectors. All thermocouple extension wire shall comply with AMS 2750.

Furnace Control Thermocouples. One control thermocouple is required per furnace control zone, and one additional thermocouple is required for over-temperature protection. All control thermocouples and over-temperature thermocouples shall be Type “S” and shall meet accuracy and calibration requirements as detailed in AMS 2750. The control and over-temperature thermocouples shall be of a non-expendable configuration. Each thermocouple shall have a corresponding temperature controller defined in Section 3.3.18 and 3.3.19.

Workload Thermocouple Port. The workload thermocouple port(s) shall support a minimum of 12 each type K thermocouples. The thermocouple signals shall be routed through a potted/sealed feed through rated for the applicable temperature/vacuum service. Thermocouple jack panels (12 each type K with standard 2 pin connectors) shall be located inside of the vacuum chamber for easy connection of load thermocouples, and outside of the vacuum chamber for connection of furnace instrument thermocouple extension wires.

The thermocouple jack panels shall be rated for the applicable temperature/vacuum service. The Workload thermocouple ports shall be mounted on the furnace door. High-temperature thermocouple wire extensions may be used to accomplish the orientation.

Temperature Uniformity Survey (TUS) Thermocouple Port. TUS thermocouple ports shall support enough thermocouples to comply with the number of TUS sensors required by AMS 2750 according to the minimum 72 inches x 72 inches cylindrical work-zone volume. Survey thermocouples and their ports shall be type K compliant. The survey thermocouple signals shall be routed through sealed feed troughs rated for the applicable temperature and vacuum service.

Survey Thermocouple Jack Panels. The jack panels shall be type K with standard 2 pin connectors. There shall be enough connections on the thermocouple jack panels to support the minimum number of TUS sensors required by AMS 2750 according to the minimum 72 inches x 72 inches cylindrical work-zone volume simultaneously. The jack panels shall be located inside of the vacuum chambers for easy connection of survey thermocouples and outside of the vacuum chambers for connection of survey/uniformity instruments. The thermocouple jack panels shall be rated for the applicable temperature/vacuum service. Internal survey thermocouple port shall be mounted on the furnace door. High-temperature thermocouple wire extensions may be used to accomplish the orientation and shall follow thermocouple extension wire requirements detailed in 3.3.6.1.

Control Cabinet Thermocouple Jack Panel. A thermocouple jack panel

(12 each type K with standard 2 pin connectors) shall be mounted externally on the furnace control cabinet in an accessible area to support 10 calibration/thermocouple certification tests. The jack panel shall be wired (extension grade type K thermocouple wire) to the same instrument connectors/terminals as the load thermocouple jack panels identified in section

3.3.6.2. and with extension grade type S thermocouple wire to the furnace temperature and over temperature Controller terminals.

Resident SAT Thermocouple Port: A type “N” resident SAT thermocouple shall be mounted in the furnace for each control zone. The resident SAT thermocouple shall be installed and positioned IAW AMS 2750 .

A labeled thermocouple jack panel shall be present on the front face (standard 2 pin connectors) of the control cabinet for each SAT thermocouple. All thermocouples, extension wire, and thermocouple connector plugs shall be type “N”.

Pneumatic System. Under the condition that a machine has a pneumatic system, the system shall conform to ISO 4414. The system shall be complete, including all valves, piping, cylinders, and pressure controls. A machine that does not require a pneumatic system to operate properly shall be considered acceptable.

Electrical System. The machine shall conform to NFPA 79 or current equivalent

ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The existing source power available at the facility is 480 Volt, 3- phase. The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated, and fused, single disconnect device shall be utilized on the machine with means of lockout in the off position only.

Electrical Enclosures. Construction of the electrical enclosures shall be in accordance with NEMA 250 type 12 or current equivalent ISO/EN/DIN/JIS/IEC standards and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to NFPA 79 or equivalent ISO/EN/DIN/JIS standards. The machine shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79 or current equivalent ISO/EN/DIN/JIS/IEC standards. Exposed wiring shall be housed in conduit conforming to NEMA FB 1. All electrical housings and cabinets shall meet the requirements of NEMA Publication 250, Type 12. All electrical wiring shall be visually tagged identifying its function and a L.E.D. to identify positive signal transmission. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Cabinet Specification. A free standing or integrated NEMA 12 control cabinet shall be provided to house all instrumentation, power meters, motor controls, relays, alarms, control power transformer, and any other accessories required, along with ventilation and cooling for the system.

Interconnecting Furnace Requirements. Complete conduit and interconnecting wiring for the furnace components shall be provided in accordance with the NFPA 79, NEMA FB 1 and ANSI/NFPA 86 AMD 1.

Ammeters and voltmeters. Ammeters and voltmeters shall be provided for each heating element bank(s). An ammeter shall be included to monitor the gas blower and motor current. Each instrument shall be identified with a nameplate for the item they represent and shall be mounted on the control panel.

Circuit Breakers. Circuit breakers shall be provided in NFPA 79 enclosures. The main power supply circuit breaker shall allow the power to the entire furnace system to be independently shut-off.

Grounding. The equipment shall have a single point grounding stud 5/8 inches diameter or larger. The resistance between the grounding stud and all other exposed metallic parts shall not exceed 2.0 OHMS

Arc Flash Protection. The machine enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” or current equivalent ISO/EN/DIN/JIS/IEC standards for arc flash safety. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall be equipped to handle the electrical load imposed by operation of the machine to its maximum potential. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

Motors. All motors shall be ball or roller bearing type and rated for continuous duty.

Each AC motor used in the machines system shall be dual voltage and suitable for its application and shall meet the requirements for either drip-proof or totally enclosed fan cooled enclosure. All motors shall meet the requirements of NEMA MG-1 or current equivalent ISO/EN/DIN/JIS/IEC standards. Power factor correction capacitors will be installed for AC motors rated at 25 HP or greater. Electric motors 75 Hp and larger shall consist of three phase construction. Where standard “V” belt drives are used, they shall be sized to transmit 150 percent of developed horsepower.

Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

Hour Meter. The machine shall be equipped with a non-resetting type, hour meter to display accumulated operating time of the drive motor(s), mounted on the main electrical panel visible from the outside, sealed to prevent the entrance of dust and moisture, and shall be mounted to withstand shock and vibration generated by the machine.

The meter shall have a range of 0 to 99,999.9 hours in increments of one (1) tenth of one

(1) hour. A CNC control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, and run time of the servo motor(s) shall be considered to meet this requirement. The meter shall be sealed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the machine.

Control Cabinets. All instrumentation and controls shall be functionally grouped, permanently identified, and conveniently located for single operator control. An alternate manual switch on the control cabinet or touch screen, shall be provided to start or turn-off diffusion pump heaters. The panel shall provide for either semi-flush mounts or flush mounts for all instruments.

Interlock and Limit Switches. All necessary controls shall be interlocked to provide maximum safety for personnel and equipment.

Instrumentation. All instrumentation and controls shall be front panel mounted in a single console. The enclosure shall be a NFPA 79 Type 12 enclosure with panel doors.

Furnace Controls. Contractor shall provide data/literature of the set point programmer and programmable logic controller design; customer references shall be provided with the proposal. The furnace set point programmer and programmable logic controller shall be configured with sufficient In/Out and logic memory capacity to ensure complete control of all furnace programs, routines, and events; and shall provide the following integrated functions:

a. Loop, logic, and sequence control

b. Data acquisition

c. Set point programming

d. Recipe storage for 60 recipes

Temperature Controller. The temperature controller shall be a Eurotherm 3504.

This instrument shall be a separate instrument from the furnace controls. A type “S” thermocouple shall be provided for the exclusive use of this instrument. The temperature controller shall be mounted on the control cabinet.

Over Temperature Controller. The over-temperature controller shall be a

Honeywell UDC 2500. The controller shall function to shut off electricity to the heating elements of the furnace in the event the over-temperature control point is reached. This instrument shall not be used for furnace cycle over-temperature condition, but only for maximum protection of the furnace. This instrument shall be manually set before each furnace run. This shall be a separate instrument with control circuitry physically separate from the main controller. A type "S" thermocouple will be provided for the exclusive use of this instrument. Should the over-temperature control point be exceeded an audible alarm shall sound.

Chart Recorder. A Yokogawa GX20 with AH option (Calibration correction schedule control function) shall be installed. The recorder shall have a minimum configuration of 16 channels to record a minimum of 12 each type K load thermocouples, as well as control thermocouple per zone, over-temperature thermocouples, vacuum level in mTorr, and one spare. The chart recorder shall be configured for the connectivity requirements of paragraph 3.3.20 as necessary. The chart recorder shall have a minimum accuracy of +/- 0.15 percent of temperature reading +/- 1 LSD.

Uninterruptible Power Supply (UPS). A UPS shall be provided to supply 30 minutes of emergency power to the controllers and MMI for proper furnace system shutdown in the event of a commercial power failure. The UPS shall provide voltage regulation to automatically correct both high and low voltages so that the controllers and MMI receives voltages within the normal range. The UPS shall also provide surge protection to all connected 115V equipment.

Man Machine Interface (MMI). The contractor shall provide a furnace control system that utilizes Allen Bradley furnace controllers; or equivalent to Allen Bradley SLC 505 series, to perform all furnace sequencing and alarm functions. Specifications for the given brand name are the minimum requirement. This non- pc-based interface shall provide:

a. All the control and interface features as specified in section 3.3.15 and 3.3.21.

b. All program features and tools that are typically provided with this option.

c. Sufficient description, illustrations, and customer references of this option shall be provided at time of proposal for evaluation purposes.

d. Color touch screen.

e. e. Alarms. A display of alarms, alarm history, and alarm values; and an alarm acknowledgment interface.

f. f. History. A display menu for review of current process data; storage, retrieval, and review of historical (archival) process data; and report generation.

Software/Programming. All software and programming requirements shall be in accordance with but not limited to the following subsections:

Controller Programming. The controller shall be programmed/configured to provide all logic control necessary for automatic furnace operation, sequencing, and safety interlocks.

Set-Point Programming. Recipe programming shall be configured such that the following parameters can be specified:

a. Ramp rates (rate of temperature rise or fall, in °F/min, for any given temperature interval).

b. Soak temperature (provides a programmed temperature hold at a specified temperature).

c. Soak duration.

d. Guaranteed Soak Band (The temperature variance about the soak temperature that work thermocouples shall meet before the Soak Duration begins).

e. Start and mode of cooling.

f. Events (Based on or initiated by parameters such as: time, process variable, or deviation).

g. Event Parameters (operator specified parameters/values that control events)

Events. The following recipe events shall be programmed/provided for operator selection.

a. Event #1: Gas Cooling (GC), at the end of a heat soak GC de-energizes the heating Elements stops the vacuum pumping cycle and backfills the furnace chamber with gas to -5-inch Hg (635 Torr). When the furnace chamber reaches -7-inch Hg (582 torr) the gas blower is activated and continues until the furnace cools to the programmed end-of cycle set point temperature.

b. Event #2: Partial Pressure. This event activates a controlled flow of argon gas through the furnace chamber at an operator-specified temperature to maintain an operator specified partial pressure. This routine may be utilized on more than one occasion during a furnace cycle (i.e., at numerous segments of furnace recipe), but shall be proceeded by a pump down to less than 0.025 Torr (25 microns).

c. Event #3: Iso-Thermal Hold

d. Event #4: Chamber Vent. Vents chamber after a positive pressure quench.

e. Event #5: Automatic leak test. This routine, when combined with Pump down, shall perform an automatic leak-up rate test on the furnace chamber.

f. Event #6: Guaranteed Soak. This event places the furnace in hold until the workload thermocouples are within an operator-specified range of the soak temperature before beginning the timed soak duration. In the event the hold time exceeds an operator specified "Excessive Soak Hold" time value, a warning alarm shall be activated to notify the operator of a potential problem.

g. Event #7: Guaranteed Vacuum Cool (OYC). GVC de-energizes the heating elements at the end of the soak segment and vacuum cools until the load thermocouples are below an operator specified temperature.

Only validated load thermocouples shall determine completion of the GVC event.

h. Event #8: Vacuum Hold. This event keeps the programmer in hold until the furnace chamber pressure is below the operator specified Vacuum Hold Pressure Set point. In the event the hold time exceeds an operator specified "Excessive Hold" time value, a warning alarm shall be activated to notify the operator of a potential problem and ask for disposition.

i. Event #9: Positive pressure quench to +5 PSIG.

j. Event # 10: Positive pressure quench to +15 PSIG.

k. Event #11: Automatic set point adjustment at soak. When programmed/selected, this event will cause the logic to alter the programmer set point to bring the workload thermocouples within a 5.4°F band of the original setpoint. In the event the thermocouple is more than 5.4°F above the original set point, an alarm will occur.

l. Event #12: Controlled Cooling (CC). This event is like Gas Cooling except that the workload thermocouples arc utilized to maintain an operator specified cooling rate. The operator specified cooling rate shall be a variable that is selectable between (and inclusive of) 20F/min and 50F/min. The programmable cooling rate is maintained/controlled by a combination of automatic control of intermittent heat, and automatic control (modulation) of cooling gas now into the furnace chamber.

Furnace Routines. The following program routines shall be configured in the furnace control system:

Pump down. This routine shall handle the pump down of the furnace (i.e.

control the sequencing of valves, vacuum pumps, and crossover points as determined by pressure conditions within the furnace) from atmospheric pressure to the vacuum level specified in torr (operator specified variable).

Once the vacuum level is reached, the furnace shall hold that level for a specified time in minutes (variable) before initiation of heat. In the event the level is not reached in a specified maximum time in minutes (variable), the furnace shall alarm and request disposition.

Over-pressure. This routine shall alarm and abort the furnace in the event, during a furnace cycle, the pressure level exceeds an operator specified pressure variable.

Over Temperature. This routine shall turn off hot zone power if the furnace or workload temperature exceeds an operator specified over-temperature level. This routine is to protect workload parts and is not the same as the Over-temperature Control.

Workload Thermocouple Rejection or Out of Spec. This routine shall read all workload thermocouples, compare these thermocouples at cycle initialization, and reflect those readings that are too high or open. In the event the "zone" as specified in the controller no longer has any working load thermocouples, a soft alarm shall be generated: The operator will have the option to continue or to abort. If more than two zones are in this condition, the system shall abort automatically. If during the cycle the workload thermocouples go out of specified band (variable bandwidth about set point temp.), the cycle shall be placed in hold until the temperature stabilizes and shall warn the operator of the problem by displaying/sounding an alarm.

Minimum Work Thermocouples. This routine monitors/counts the work thermocouples and if the number of "good" thermocouples falls below a (variable) specified minimum during the cycle, an alarm shall be activated, and the system shall be placed in a "hold" condition until operator acknowledgment of the alarm. Alarm acknowledgment shall prompt a question or "continue" or "abort"?

Abort Routine #1. This routine, when operator initiated, first vacuum cools the furnace workload to a specified (variable) temperature and then gas fan force cools to a final specified (variable) temperature.

Abort Routine #2. This routine, when operator initiated, shall gas fan force cool the furnace workload from the current temperature to a specified (variable) temperature (degrees Fahrenheit).

Alarms. In addition to alarms initiated by the above referenced routines, the following alarms (and any additional alarms that the Contractor routinely provides or believes are necessary) shall be displayed/sounded to notify furnace operators of the following events:

a. Insufficient cooling water flow to furnace.

b. Excessive cooling water temperatures.

c. Excessive cooling water pressure.

d. Insufficient gas supply pressure (argon).

e. Furnace over temperature.

Power Supply Requirements. The furnace power supply shall have 3 phase, 460 volt, water cooled, variable reactance transformers (VRT), including an SCR type linear power controller. Independent "trimming control" shall provide ability to adjust each zone of power to permit manual temperature alignment. Controllers and instruments shall be operated using 115 volt nominal, 60 Hz input. The 115 volt input line shall be equipped with a filter to protect the system from line spikes and variations. 555KVA Variable Reactance Transformer with a 5 year Manufacturer’s warranty.

Trimming Requirements. The hot zone shall have a minimum of two (2) separate zones (Section 3.3.2). Trimming devices shall provide the means to adjust the power distribution for optimum temperature uniformity.

Safety Interlocks. The furnace system shall have safety interlocks to ensure failsafe operation and protection to the equipment, operator, and workload parts.

Feed- through Guards. The power feed-through located on the chamber body shall be safety protected by guards.

Accessory Equipment. The following accessory equipment shall be provided for the furnace.

a. Load-Truck. One load-truck (and rail set) shall be provided for the furnace. The up/ Down, in/out type load-truck shall be used to transport parts, work grids, survey racks and load/ unload same from the furnace.

The load-truck shall have a positive guidance/alignment feature to prevent damage of the hot zone during loading and unloading operations.

b. Accumulator Tank. An argon accumulator tank shall be provided. The tank shall be sized to provide a minimum of four times the furnace chamber volume in cubic feet of argon. On demand, the tank shall provide sufficient gas as needed to meet argon requirements for the 2 Bar Gas Quench system in Section 3.3.5.1. In addition, the accumulator tank shall provide backfill to permit the operator to open a cold furnace.

c. Survey Rack. One survey rack of sufficient size, configuration, and material (2300° FI 5 x 10.6 torr vacuum) shall be provided to support measurement of hot zone uniformity. The survey racks shall have thermocouple wells positioned in accordance with AMS 2750 requirements for furnace work-zone volume.

Performance. The machine shall meet the following minimum requirements.

a. Temperature range. The furnace shall operate in the qualified operating temperature ranges detailed in Table 1 of section 3.4

b. Heating rate. The furnace heating rate shall raise a 2000-pound gross load of nickel at a rate of 20 degrees Fahrenheit, 40 degrees Fahrenheit, and 60 degrees Fahrenheit per minute throughout the qualified operating temperature range 1 located in Table 1 of section 3.4

c. Cooling rate. The furnace argon gas cooling system shall control cooling an 1800-pound gross load of jet engine components with an additional 200-pounds of…