Attachment B- Minimum Specifications_500lb VIM-final.docx

89243320QFE000192

Attachment B

Minimum Specifications Vacuum Induction Melting (VIM) and Casting Furnace (DE-SOL-NEW) The U.S. Department of Energy (DOE) National Energy Technology Laboratory (NETL) has an immediate need for a controlled atmosphere induction melting and casting furnace to melt and cast Iron-base, Nickel-based and other metallic alloys. The vendor shall provide a “turn-key” system, meaning they will include all the necessary equipment, accessories, hardware, and control software such that after the furnace is commissioned and training is provided, melting of alloys can commence immediately. Vendor shall provide the vacuum furnace chamber, power supply, induction coil, vacuum system, PLC (HMI), accessories, furnace start-up and on-site (at NETL) training on furnace operations. The furnace shall be delivered to NETL at 1450 Queen Avenue SW, Albany, OR 97321.

All quote responses shall include a detailed description of how the proposed equipment/instruments meets the specifications described in this solicitation. The response shall include model numbers and performance specifications of all components.

The following are the minimum specifications for the VIM:

General The vacuum induction melting furnace (VIM) shall be designed to accommodate melting steel and nickel alloy ingots up to 500 pounds in weight, and shall be designed to melt alloys at temperatures up to 1650C and pour into a mold 60 inches high. Melting and casting (pouring) shall be performed under vacuum or inert gas atmospheres.

Power Supply The vendor shall provide power to the melting coil from an induction power supply rated at a minimum of 200kW. Input voltage will be 480, 60Hz, three phase. All necessary external and internal power connections are to be provided.

Vacuum Chamber for Melting and Casting A vacuum chamber shall be suitably arranged to incorporate the melt box, mold, and accessories. The chamber shall be double-walled, water-cooled and constructed of a suitable material. The use of stainless steel for the water-cooled sections of the chamber shall be offered as an option. Access to the melt coil and mold is made by way of chamber doors. The design of the doors and location of the mold table are to facilitate excellent access to the melt chamber for loading and unloading of molds as well as for servicing the melt coil and loading melt stock. The melt coil will be attached to the upper door and be accessible for loading and maintenance operations with the assistance of a forklift truck. The chamber will also include integral sight ports for viewing melting and pouring operations. The melt furnace coil and melt cradle shall be mechanically tilted and allow for tilting at least 100 degrees in the pour direction and at least 10 degrees in the opposite direction. The melt cradle shall be designed to accept 500 lb furnaces. The chamber shall be equipped with the required power ports, over pressure re-settable rupture ports and vacuum ports, inert gas port, water inlet and outlet connections and ports for required instrumentation and vacuum gages. The chamber shall also include: two (2) 6 inch view ports (with manual view port shutter guards) for viewing the melting and pouring operations. The chamber will also include one (1) 6 inch blanked off port near/above the melt coil to facilitate future modifications. The chamber will incorporate melt bath temperature measurement equipment.

A mechanically actuated thermocouple probe assembly shall be offered as an option. The assembly shall be isolated from the chamber and be subsequently pumped down to the same level of vacuum as inside the melt chamber. It shall be capable of thermocouple probe tip replacements during furnace operations.

A two-color optical pyrometer with a sight port shall be offered as an option. The pyrometer should be capable of monitoring the melt temperature in the range 1100 to 3200 °C at a minimum. The unit should have its own sight port on top of the melt chamber and have a manual port shutter guard.

As a separately priced option the vendor will quote a 4-cup additions charger mounted external to the chamber, controlled with external handles. The charger will have four (4) canisters and a discharge chute to feed the crucible. The charger is external to the melt chamber with a manual isolation valve and can be subsequently pumped down to the same level of vacuum as inside the melt chamber.

Melt Coil Assembly A furnace assembly with a 500 pound steel capacity induction melting coil mounted in it is to be provided including a coax feed through providing both power and water to the melt coil. All water and electrical terminals shall be included. Tilt is accomplished by means of a tilting frame assembly mounted to the melting chamber door. Pouring is accomplished by a hydraulic motor mounted externally to the vacuum chamber. The tilting frame assembly shall be provided with the ability to adjust in the X, Y and Z directions during mechanical setup such that the molten metal stream will remain in alignment with the mold during the pour.

Vacuum System The vacuum system requirements are as follows: Ultimate vacuum of 10-3 torr (1 micron); and leak rate of 30 microns/h are the minimum requirements. The vacuum system shall consist of mechanical pump, roots-style blower, and diffusion pump. The vendor shall also supply at least one KF fitting (size 16 or 25) on the main furnace body to facilitate connecting to customer supplied vacuum gauges.

Water Distribution Manifold The vendor shall supply a manifold to provide cooling water to all systems that require cooling (melt chamber, melt coil, vacuum system, electrical circuits, etc.). The cooling water system shall consist of an inlet manifold, including a pressure gauge, with individual ball valves and nipples from the manifold, properly labeled for each circuit. Furnace cooling water lines terminate at a closed manifold with temperature gauges and flow switches on critical circuits. The sensitive/critical high frequency portion of the power supply shall be cooled with a closed loop heat exchanger connecting to the house water to facilitate cooling with DI water or equivalent. Note that emergency cooling water is supplied integral to the house cooling water system at NETL.

Safety Devices The vendor shall supply safety devices to insure safe operation of the furnace. These include a 1.5” diameter spring loaded pressure relief valve on the chamber to prevent positive pressure build up in the chamber. Also required are water flow switches to protect the induction coil and furnace chambers against water failure or water starvation. Also required are limit switches and interlocks ensure the correct sequence of events. Also required are switches and interlocks to ensure the correct sequencing of the vacuum valves and pumps.

Inert Gas and Air The vendor shall supply an inert gas connection consisting if the following: manual shut-off valve behind a line connecting to the house Argon, Nitrogen supply. A manually operated air admittance valve will be fitted to the melt chamber. When opened, this valve restores atmospheric air pressure in the melt chamber and allows the chamber door to be opened.

Control System The vendor shall provide the control system assembled in an enclosed panel (controls enclosure). The panel will be fully wired and connected between the auxiliary equipment mounted on the furnace. Included will be the PLC for furnace control, a color touch panel and an emergency stop button.

The color touch panel will provide multiple graphic displays such as the furnace system pumps, valves, instrument sensors (vacuum and immersion thermocouple), as well as a series of alarm lights. This panel will be mounted on the furnace platform. It will be programmed such that the status of valves and vacuum pumps can be visually determined by viewing the graphic.

The PLC will be programmed to allow sequential vacuum pump down of the melt chamber. All necessary interlocks will be provided to ensure proper sequential operation of the system and to avoid inadvertent damage to various components.

Pre-Pipe and Wire The vendor shall provide electrical control wiring, and water and hydraulic or pneumatic lines integral with the furnace assembly. The vacuum chamber and pumping system shall be factory assembled for fit-up and vacuum leak checking. The vacuum system control wiring shall be installed and terminated in a junction box. Marked terminal strips are to be provided for control wiring to be connected on site at NETL between the junction box and the control panel.

Startup Service Commissioning and Training The vendor shall set up and test the equipment prior to shipping. Testing shall include (but not be limited to) vacuum level, vacuum leak rate, operation of all valves and controls, operation of the HMI/PLC controls, operation of the power supply. After NETL has installed the equipment, the vendor shall come to the installation site for initial commissioning which will include checking the installation, initial startup, as well as train NETL personnel on the operation, maintenance of the furnace. This shall occur at NETL, 1450 Queen Ave. SW Albany OR 97321. This commissioning and training shall be sufficient for safe, reliable operation of the furnace.

Documentation Two sets of electronic copies of operating and maintenance manuals shall be provided within 2 months of the contract being awarded. Two sets of electronic copies of assembly drawings shall be provided with the furnace.

Warranty A one (1) year warranty shall be provided. The warranty shall be one year from the date of service commissioning (above).

NRTL Certification All the equipment provided by the vendor shall be electrically inspected by a Nationally Recognized Testing Laboratory and certified prior to acceptance by the Government. This will be inclusive of but not limited to the power supply, induction coil, vacuum system, PLC, accessories, etc. To include Factory Acceptance Testing and field inspection at NETL, 1450 Queen Ave. SW Albany OR 97321.

Freight FOB shipping to NETL 1450 Queen Ave. SW Albany OR 97321