FPI_SOW_28_May_19.pdf

Statement of Work

FLUORESCENT PENETRANT INSPECTION UNIT

28 May 2019

Requirement: The contractor shall provide Fluorescent Penetrant Inspection (FPI) Unit and filtration unit. In accordance with MIL‐PRF‐32531, FLUORESCENT PENETRANT INSPECTION (FPI) UNITS, SEPARATE

MODULAR STATION TYPES. Classification is Type II (Post‐emulsified with aqueous developer), Size 5 (PT‐

48), Class A (Unpowered tanks), and Standard Form (L‐to‐R processing). Other applicable documents can be found in Para 2 through 2.4. MIL‐PRF 32531.

1. Additional Items: A warranty of at least 12 months from the date of instalment covering parts and labor shall be provided. Additionally training and support shall be provided for personnel on the operation and maintenance of all elements of the penetrant line. Technical manuals shall be provided with the following guidance.

1.1 FPI unit should include a paper and electronic (CD‐ROM) copy of the installation (including minimum utility requirements and procedures to change input voltage), operation, and maintenance instructions, and an Illustrated Parts Breakdown. The documentation should list part numbers for replaceable items, such as lamp bulbs, filters, curtains.

2. EQUIPMENT LOCATION: The contractor will be responsible for all parts, materials, transportation, and labor to deliver or ship (direct shipping only, not through consolidation point) and install all aforementioned items. NDI specialist will accomplish a verification/examination inspection in accordance with MIL‐PRF 32531 Para 4. thru Para 4.4.25 upon installation. During verification/examination of the FPI unit, the contractor will be responsible for any deficiencies identified and will correct all deficiencies prior to government acceptance. The contractor shall assemble and install the FPI unit upon delivery, to RAF Mildenhall NDI Lab, Bldg. 814 Rm 59. The contractor must coordinate all deliveries with the POC (Steven Izaguirre). All deliveries will be made

Monday through Friday, between 8:00AM and 2:00PM local time, excluding US and UK holidays.

3. Specifications The specifications for fluorescent penetrant inspection (FPI) unit are as follows in accordance with MIL‐

PRF‐32531;

Design and construction. (Para 3.2 MIL‐ PRF 32531)

The FPI units shall be designed and constructed to perform complete and efficient penetrant inspections of parts and assemblies in accordance with ASTM E1210 and ASTM E1417/E1417M. They shall be constructed to hold aerospace components or similar parts and inspection materials without deformation of the components. The units shall be designed and constructed so that during the normal inspection process there will be no leakage of penetrant, remover, developer, and/or water within the area bounded by the outermost extremities of the inspection unit; nor shall they leak from station to station, except for the penetrant drain station back to the penetrant station. All welds shall be aerospace quality in accordance with TO 00‐25‐252. All tanks shall be inside fillet welded. All welds shall be continuous across their respective sections. All carbon‐steel components shall be hot‐dip galvanized per ASTM A123/A123M or inorganic zinc‐rich coated per SSPC‐Paint 20, type I as a primer. The paint finish system used shall resist degradation or attack from the chemical systems used in the fluorescent penetrant inspection process. The exterior paint color shall be the same on all stations; however the interior of the inspection station shall be painted flat black in color. Roller grilles shall have a capacity of

250 pounds supported by only two rollers.

Type II stations. (Para 3.4.2 MIL‐ PRF 32531) The inspection units shall consist of the following stations: penetrant tank, penetrant drain, pre‐rinse, remover tank, wash (remover‐rinse), aqueous developer tank, developer drain, dryer, rest, and inspection station

Station 1. Penetrant Dip Tank Construction: 304 Stainless Steel Box Section with 16SWG

Stainless Steel Tank and Paneling

Dimensions: 43” (L‐R) x 29” (F‐B) x 26” (Deep) Internal

Working Height 36”

Fittings: Stainless Steel Hinged Lid

High Level Drain Tap 4” from the Base

Low Level Drain Tap Located in the Base

Stainless Steel Base Grille

(See Para 3.4.6 Penetrant Tank Station MIL‐ PRF 32531)

Station 2. Penetrant Side Drain Construction: 304 Stainless Steel Box Section with 16SWG

Dimensions: 43” (L‐R) x 29” (F‐B) x 6” (Deep)

Working Height 36”

Fittings: Integral with Drain back to Penetrant Dip Tank

Roller Grille Platform (Removable for Cleaning)

(See Para 3.4.7 Penetrant Drain Station MIL‐ PRF‐ 32531)

Station 3. Pre Rinse Station Construction: 304 Stainless Steel Box Section with 16SWG

Dimensions: 43” (L‐R) x 29” (F‐B) x 26” (Deep) Internal

Working Height 36”

Fittings: Back Splash

LH Side Splash see U/V Booth RH Side slides to the Rear

Water Heater 50 – 100 °F Shared with Station 5

Air & Water Pressure Regulators with Digital Displays (PSI)

Water Temperature Regulator with Digital Display (PSI)

Air/Water Gun

Overhead Splash‐proof U/V light

Stainless Steel Base Grille

(See Para 3.4.8 and 3.4.8.1 Pre Rinse Station MIL‐ PRF‐ 32531)

Station 4. Remover Station Construction: 304 Stainless Steel Box Section with 16SWG

Dimensions: 43” (L‐R) x 29” (F‐B) x 26” (Deep) Internal

Working Height 36”

Fittings: Stainless Steel Hinged Lid

High Level Drain Tap 4” from the Base

Low Level Drain Tap Located in the Base

Stainless Steel Base Grille

Back Splash and Sides Shared with Stations 3 & 5

Air Agitation System with Air Pressure Regulator &

Digital Display (PSI) On/Off Switch to the Front

(See Para 3.4.9 and 3.4.8.1/.2 Remover Station MIL‐ PRF‐ 32531)

Station 5. Wash Station Construction: 304 Stainless Steel Box Section with 16SWG

Dimensions: 43” (L‐R) x 29” (F‐B) x 26” (Deep) Internal

Working Height 36”

Fittings: Back Splash

LH Side Splash slides to the Rear RH Side see U/V Booth

Water Heater 50 – 100 °F Shared with Station 3

Air & Water Pressure Regulators with Digital Displays (PSI)

Water Temperature Regulator with Digital Display (PSI)

Air/Water Gun

Overhead Splash‐proof U/V

Base Grille

(See Para 3.4.10 Wash Station MIL‐ PRF‐ 32531)

Station 6. U/V Booth Enclosing Construction: Mild Steel Box section with 16SWG Mild Steel

Stations 3, 4, and 5 Panels Powder Coated Internal Matt Black and

Externally in your Preferred Ral Color (TBA)

Dimensions: 140” (L‐R) x 72” (F‐B) x 84” (High)

Fittings: Brush Slot to Roof to allow for Overhead Hoist access

U/V and White Background Lights and Extraction Fan

Pneumatic Entry and Exit for Components (See Dwg)

*(See Para 3.4.10.4 Roof MIL‐ PRF‐ 32531)

Station 7. Developer Station Construction: 304 Stainless Steel Box Section with 16SWG

Dimensions: 43” (L‐R) x 29” (F‐B) x 26” (Deep) Internal

Working Height 36”

Fittings: Stainless Steel Hinged Lid

High Level Drain Tap 4” from the Base

Low Level Drain Tap Located in the Base

Stainless Steel Base Grille

Air Agitation System with Air Pressure Regulator &

Digital Display (PSI)

(See Para 3.4.11 Remover Station MIL‐PRF‐32531)

Station 8. Drain Station Construction: 304 Stainless Steel Box Section with 16SWG

Dimensions: 43” (L‐R) x 29” (F‐B) x 6” (Deep)

Working Height 36”

Fittings: Fixed Drain Pan

Removable Drain Pans with Handles for Lifting

Roller Grille Platform for Component Drain

(Removable for Cleaning)

(See Para 3.4.12 Remover Station MIL‐ PRF‐ 32531)

Station 9. Drying Oven Construction: 304 Stainless Steel Box Section with 16SWG

Dimensions: 68” (L‐R) x 29” (F‐B) x 26” High (Internal)

Fittings: Tunnel Configuration with Pneumatic Entry & Exit Doors

Roller Grille Platform Internal

Double Skinned with Insulated Walls

Re‐Circulating Hot Air Thermostatically Controlled to a

Maximum Temperature of 200 Deg F (TBC)

(See Para 3.4.13 Drying Station MIL‐ PRF‐ 32531)

(See Paras 3.4.13.1 Controls & 3.4 13.2 Curtains MIL‐ PRF‐ 32531)

Station 10. Rest Station Construction: 304 Stainless Steel Box Section with 16SWG

Dimensions: 43” (L‐R) x 29” (F‐B) x 6” (Deep)

Working Height 900mm

Fittings: Roller Grille Platform for resting rollers at 4”

Centers with Non – Corrodible Roller Bearings

Removable Drain Pans with Handles for Lifting

Air Blow off Gun Regulator and Digital Display

(See Para 3.4.15 Rest Station MIL‐ PRF‐ 32531)

Station 11. Inspection Station Construction: Mild Steel Box section with 16SWG Mild Steel

Panels Powder Coated Internal Matt Black and

Externally in your Preferred Ral Color (TBA)

Dimensions: 72” (L‐R) x 60” (F‐B) x 96” (High)

Fittings: Brush Slot to Roof to allow for Overhead Hoist access

U/V and White Background Lights and Extraction Fan

Component Pneumatic Entry & Exit Doors

Inspection Bench with Roller Grille & Dust Pans Below

(Removable for Cleaning)

72” (L‐R) x 29” (F‐B) x 36” (High)

Storage Shelf

(See Para 3.4.16 Inspection Station MIL‐. PRF‐ 32531)

Voltage.

All wiring, insulation, and electrical components shall be in compliance with the NFPA 70. Dryer heater element(s) in sizes 2 through 5 shall be capable of operating from both 208 and 240 VAC, 50 and 60

Hertz. The size 6 dryer heater element(s) shall be capable of operating from 208, 240 and 480 VAC, 50 and 60 Hertz. The heater elements shall be the only components to operate directly from line voltage above 120 VAC. The initial line operating voltage shall be 240 VAC unless otherwise specified by the procuring activity. The rest of the equipment shall operate from 110‐120V, 50 or 60 Hertz, single phase

AC source and shall be Ground Fault Circuit Interrupter (GFCI) and circuit breaker protected. The unit shall require a single connection to each source (only one 120V and only one 208V, 240V, or 480V source). An Electrical Identification Plate shall be affixed to the back of the unit near the higher voltage connection. Each motor shall have an electrical identification plate showing manufacturer, model, serial number, horsepower, voltage, amperage, and frequency.

Electrical controls.

Each blacklight, white light, exhaust fan, dryer heater circuit, dry developer station, and pump shall operate independently of any other unit and shall have a separate control or switch.

Nozzles.

The nozzles at the pre‐rinse and remover‐rinse stations shall have a spring‐operated, lever‐type hand swivel valve and be of the fan/conical‐shaped coarse spray type. Nozzles that have adjustable spray patters shall not be used. The delivery rate of the nozzles shall be not less than three (3) gallons per minute, and not more than six (6) gallons per minute at 40 psi pressure.

Blacklights.

The blacklights which are employed to fluoresce the inspection medium shall have an initial intensity of 2000 microwatts per square centimeter at 15 inches. The blacklight wavelength shall be in the range of 320 to 380 nanometers (nm), with a peak intensity of 365 nm. A ten minute warm‐up is allowed before blacklight measurements. The lights shall be supported by adjustable brackets and directed toward the part to be inspected. The lights shall be readily dismountable from the adjustable brackets without removing or loosening any fasteners for fixtures, and have an insulated handle for inspector use. Except the blacklight lens itself, no part of the blacklight may exceed 120 °F in operation to prevent injury to personnel. If the blacklight lens itself exceeds 150 °F, “standoffs” are required to keep the lens from touching other materials when the blacklight is placed face down in the inspection station. Mercury‐ vapor blacklights are to be used unless otherwise specified.

Baskets.

Six wire baskets, with handles, made of corrosion resistant stainless steel shall be provided with the unit. They shall have hooks on one side to suspend the basket from the inside‐front‐top of the tank while allowing the tank covers to close. Unless otherwise specified, the baskets shall have dimension of

12 inches long x 8 inches wide x 6 inches deep and a maximum mesh opening of 1/2 inch square.

Trays

Welded aluminum processing trays shall be provided with the unit. Quantity and sizes shall be per table

V. The rectangular tray frame shall be made from aluminum angle stock with a leg of 1.5 inches and a thickness of 3/16 inches. Welded inside the frame shall be 14 gauge (0.063 inch) perforated aluminum sheet. Perforated hole diameter shall be 0.25 to 0.5 inch.

CARBON FILTER SYSTEM

A carbon filter system is designed to treat waste waters created by the penetrant inspection process prior to the discharge to drain. A filtration system will be needed with these dimensions 40” (L‐R) x 70”

(F‐B) x 76” (High)

The contractor will provide a filtration system that would work using a sump system where waste water will be drained from both the first and second stage rinse stations. The sump will then contain a float switch activated pump which will transfer the waste waters to the carbon filter unit. The carbon filter unit will then feature a 3 stage filter system with varying sized of media along with activated carbon granules which the waste water will pass through before discharging the treated water to drain.