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12964-11-002A

SPEC NO. 12964-11-002A

28 June 2011

EQUIPMENT SPECIFICATION

FOR

ALLIS CHALMERS VA-1409 AXIAL COMPRESSOR ROTOR BARREL

ARNOLD ENGINEERING DEVELOPMENT CENTER

ARNOLD AIR FORCE BASE, TN 37389-9998

Not AEDC STINFO

TABLE OF CONTENTS

1. Scope

2. Applicable Documents

2.1 Government Documents

2.2 Non-Government Documents

3. Requirements

3.1. Description

3.2. Qualifications

3.3. Material Properties

3.4. Manufacturing

3.5. Workmanship

3.6. Submittals

4. Quality Assurance

4.1. Responsibility

4.2. Tests and Verifications

4.3. Quality Conformance Inspections

4.4. Acceptance

5. Packaging

6. Notes

6.1. Compressor Performance Conditions

Figure 1

Appendix A – Submittal Procedure

Page-1

1. SCOPE

1.1 This specification establishes material, labor, manufacturing, testing, inspection, and delivery requirements for one (1) rotor barrel discharge end for an Allis Chalmers VA-1409 axial compressor (S/N 5302). The compressor rotor body discharge end is a component of an Allis Chalmers compressor used at Arnold Engineering Development Center (AEDC), Arnold Air Force Base, Tennessee.

1.2 Government-furnished equipment: The Government will lend the Contractor the following items for use during this contract:

A. Rotor Blades: Rotor blades (5 blades: 1 blade per row)

B. Blading Taper Gauges: Taper gauges (2 each: 1 per taper hole size)

2. APPLICABLE DOCUMENTS

2.1. Government Documents:

2.1.1. AEDC Drawings.

A. PU208618 Rev F – Rotor Body/Discharge End

B. PU630885.01 Rev B – Rotor Blade/Assembly

C. PU208716 Rev A – Inspection Data Sheet

2.2. Non-Government Documents: The following documents form a part of this specification to the extent specified herein:

2.2.1. Codes and Standards:

A. ASTM International:

1. ASTM A370-10 Standard Test Methods and Definitions for

Mechanical Testing of Steel Products.

2. ASTM E-23-91 Standard Test Methods for Notched Bar

Impact Testing of Metallic Materials.

3. ASTM E-45-87 Standard Test Methods for Determining the

Inclusion Content of Steel.

4. ASTM E-112-88 Standard Test Methods for Determining

Average Grain Size.

5. ASTM A723/A723M-10 Standard Specification for Alloy Steel

Forgings for High-Strength Forgings for High-Strength Pressure Component Application.

B. International Organization for Standardization:

Page-2

1. ISO 9001-08 Quality Management Systems- Requirements, Fourth Edition.

C. SAE International

1. SAE AMS 6427K-09 Steel Bars, Forgings, and Tubing.

3. REQUIREMENTS

3.1 Description: The rotor barrel discharge end shall be a steel forging, heat treated and precision machined to the dimensions and tolerances specified on drawing PU208618 Rev F.

3.2 Qualifications: All work shall be accomplished at a facility with current ISO 9001:2008 certification in the repair of turbo-machinery and associated equipment.

3.3 Material Properties: The forging material for the rotor barrel shall be heat treated to meet the minimum mechanical properties shown in Table 1.

Table 1 - Mechanical Properties

Tensile strength, PSI, Min. 120,000

Yield strength @ 0.2% offset, PSI, Min.

105,000

Yield strength @ 0.2% offset, PSI, Max.

120,000

% Elongation, Min 17

% Reduction of area, Min. 45

Charpy V-notch @ -20ºF, Ft. Lbs., Charpy V-notch @ 70ºF, Ft. Lbs., Brinell Hardness 241-285

3.4 Manufacturing:

3.4.1 Fabricate the rotor barrel discharge end in accordance with AEDC Drawing No.

PU208618 Rev F.

3.4.2 Type of Forging: The hollow barrel shall be cylindrical in configuration.

3.4.3 Forging Material: Forging material for the hollow barrel shall be AISI 4330 V-modified vacuum-processed alloy steel which meets AMS 6427K, complies with mechanical properties specified in Table 1, and satisfies the quality provisions of paragraph 4.

3.4.4 Grain Size: The austenite grain size of the forgings shall be predominantly 6 to 8 and finer, with isolated 4’s, not to exceed 5 percent, determination made in accordance with ASTM E-112.

Page-3

3.4.5 Microstructure: The microstructure of the forging shall be a uniform fine-grained martensite with a maximum of 5 percent evenly distributed ferrite.

3.5 Workmanship: The heat-treated forging shall be free of seams, segregations, cracks, flakes, dendrites, and injurious stringers that will not be removed during final machining. Machined surfaces, particularly pilots, shall be smooth and free of burrs and discontinuities. Welding to any component on the rotor assembly shall not be permitted and is cause for rejection.

3.6 Submittals: Submit the following in accordance with Appendix A – Submittal Procedure.

3.6.1 Submittal Table:

No. Reference No. Submittal Description Due

1 4.2.1B Submit sample wafer of the forging After forging but before heat treatment

2 4.2.1B Submit sample wafer of the forging Immediately after heat treatment

3 4.2.1C Mechanical properties Following mechanical tests

4 4.2.2 Ultrasonic Inspection report by Certified Level II MPI/UT Inspector

After heat treat

5 4.2.3 Magnetic Particle Inspection results by Certified Level II MPI/UT Inspector

After final machining

6 4.2.4 Inclusion Cleanliness Content Following metallurgical confirmation

7 4.3A As-built dimensions on drawing After dim inspection

8 4.3B Blade – Taper Fit Inspection Results After taper fit measurements

9 4.3C

Rotor Barrel Runout Inspection Report After run out measurements

Table 2 – Required Submittal List – Completed.

4. QUALITY ASSURANCE

4.1 Responsibility. The Contractor shall perform all tests and inspections to ensure compliance with requirements. The Contractor shall document and provide the Contracting Officer with all test verifications (4.2) and quality inspections (4.3).

4.1.1 The Government reserves the right to witness all testing. The Contractor shall notify the Government two weeks prior to performing the following tests and inspections:

A. Ultrasonic testing of the forging before machining.

B. Metallurgical inspection of the forging before finish machining.

C. Magnetic particle inspection after final machining.

Page-4

4.2 Tests and Verifications.

4.2.1 Mechanical Properties. Contractor shall take test wafers from one end of the forging in accordance with attached Figure 1, machined in a direction transverse to the longitudinal axis of the forging.

A. Contractor Test Wafers. Test wafers shall be removed from one end of the forging in accordance with Figure 1. The test wafers shall be removed from the rear end of the rotor barrel discharge end. All test wafers, except macrostructure and grain size wafers supplied to the Government, shall remain a part of the forging until final heat-treating has been completed.

B. Government Test Wafers. After forging, but before heat treatment, the

Contractor shall submit a sample wafer of the forging (refer to Figure 1) to the Contracting Officer for examination of macrostructure, determination of grain size, and inclusion examination. Immediately after heat treatment, the Contractor shall submit an additional wafer of the forging to the Contracting Officer for confirmation of mechanical properties and microstructure. The drawing number shall be affixed to the wafer.

C. Test Procedure. The test specimens machined from the wafers shall be tested in accordance with ASTM E-23. The Contractor shall determine the transverse mechanical properties at room temperature, including hardness, ultimate tensile strength, yield strength at 0.2 percent offset, impact strength (Charpy V-notch), percent elongation, and percent reduction of area. The Contractor shall also determine the percent shear of the impact specimens. Submit results to the Contracting Officer.

4.2.2 Ultrasonic Inspection. After heat treatment, a Certified Level II MPI/UT

Inspector shall inspect the forging in accordance with ASTM A723/A723M-10 and submit inspection results. Calibration criteria are as follows:

4.2.2.1 Straight Beam (longitudinal) #8 DAC (distance-amplitude correction) shall be performed by Certified Level II MPI/UT Inspector:

A. Record any indication exceeding 50 percent of the reference level.

B. Record any indication exceeding the resultant back reflection.

C. Reject any indication equal to or larger that the reference level.

D. Reject any indication which is accompanied by a complete loss of back reflection.

E. The test-metal distance to the flat bottom calibration holes shall be equal to approximately 25 percent of the anticipated scanning distance. The calibration block shall be fabricated from material which is ultrasonically similar to that being tested.

4.2.2.2 Angle Beam (shear).

Page-5

A. 60 V-notch x 1.0 inch long and 3 percent radial wall thickness deep or .25 inch, whichever is smaller.

B. Record indications equal to or exceeding 50 percent of the reference level.

C. Reject indications which exceed the reference level.

4.2.3 Magnetic Particle Inspection. After final machining, the forging shall be inspected by Certified Level II inspector (MPI/UT) both longitudinally and circumferentially in accordance with ASTM A723/A723M. Submit report of results.

A. Full wave or half wave rectified Alternating Current (AC) shall be used.

B. Application of particles shall be by wet fluorescent method.

C. De-magnetization is required.

4.2.4 Inclusion Content. The rotor barrel forging material shall be examined for cleanliness in accordance with ASTM E45-87, Method “B”. The minimum acceptable cleanliness shall be 4-3 B. The specimen shall be submitted to the Government for metallurgical confirmation. Specimens for inclusion content shall be taken at the inside diameter of the forging.

4.3 Quality Conformance Inspections. Perform the following quality conformance inspections for the forging:

A. Dimensional Inspection. The finished machined forging shall be dimensionally inspected to ensure compliance with drawing PU208618 Rev F. Record all “as-built” dimensions in the drawing and submit to the Contracting Officer.

B. Blade – Taper Fit Inspection. Each tapered blade hole located in the barrel shall be inspected for percentage contact area and depth, using the taper gauges supplied by the Government. Surface contact between blade and barrel tapers shall be a minimum of 90 percent. Taper depth shall be checked to determine blade-to-barrel clearances are adequate.

Clearances between blades and barrel shall be in accordance with blade installation drawing PU630885.01 Rev B. Record and submit results to the Contracting Officer.

C. Rotor Barrel Runout Inspection. Runout measurements shall be taken and recorded for the rotor barrel in accordance with AEDC Drawing PU208716 Rev A. Submit report of results to the Contracting Officer.

D. In the event a non-conformance to the specification should arise and the contract item cannot be reworked back to specification, contact the Contracting Officer immediately.

4.4 Acceptance. The Government will perform the following inspections after delivery of the rotor barrel to AEDC prior to final acceptance:

Page-6

A. Visual inspection.

B. Dimensional inspection.

5. PACKAGING

5.1. The Contractor shall provide all preservation, packing, and packaging to ensure safe delivery of the finished machined rotor barrel discharge end to AEDC, Arnold Air Force Base, Tennessee. Finished surfaces shall be adequately protected to prevent marring, scratching, rust, and contamination.

5.2. Packaging shall include all rotor blades and blade taper gauges provided by the Government for the Contactor’s use.

6. NOTES

6.1. Compressor Performance Conditions:

6.1.1. Rated Operation Conditions:

A. Service: Air

B. Inlet Pressure: 5.0 PSIA

C. Discharge Pressure: 16.5 PSIA

D. Pressure Ratio: 3.3

E. Inlet Volume: 280,000 CFM

F. Inlet Temperature: 100ºF

G. Discharge Temperature: 415ºF

H. Operating Speed: 3600 RPM

6.1.2. Maximum Operating Conditions:

A. Inlet Pressure: 13.33 PSIA

B. Discharge Pressure: 27.2 PSIA

C. Inlet Temperature: 165ºF

D. Discharge Temperature 500ºF

Page-7

FIGURE 1

Attachment A – Submittal Procedure

Figure 1

NOTES:

1) Material with 10.00 inch and larger O.D. and minimum wall thickness (W) of 2.12 inches, use suitable ASTM Standard Specimens E23-91 and A370-10.

2) Specimens 3AT, 3AI, and 4AT, to be located within .06” O.D.

3) Specimen 1AT and 1AI to be located within .06 of I.D.

4) Specimens 2AT and 2AI to be located at A/2 and E/2 as shown.

5) Typ. Specimen designation to be stamped on end of each specimen:

2 A I

6) Laboratory report to give results of each specimen examined.

7) Laboratory report to include component code, serial number, Drawing/part number as applicable.

8) Wafer “A” to be removed prior to heat-treatment and furnished to AEDC for review (see 4.2.1) Identify wafer with purchase order number and stamp

“NOT HEAT-TREATED”.

9) Wafer “B” to be removed after heat-treatment, but prior to fabrication, for test by the contractor (see 4.2.1).

10) Wafer “C” to be removed after heat-treatment, but prior to fabrication, and furnished to AEDC for confirmation of material condition (see 4.2.1).

Identify wafer with purchase order number and stamp “HEAT-TREATED.”

11) Six-inch wide test material may be furnished in lieu of entire wafer for forging diameters greater than 15 inches (see above sketch).

“I” Impact (T Tensile)

Wafer “A”

Specimen No.

FIGURE 1: ROTOR BARREL FORGING – SPECIMEN LOCATIONS

Appendix A-1

APPENDIX A

SUBMITTAL PROCEDURE

PART 1 GENERAL

1.1 DESCRIPTION OF REQUIREMENTS. This section specifies procedural requirements for non-administrative submittals, including but not limited to shop drawings, product data, manufacturer’s certificate, design data, calculations, and verifications, manufacturer’s instructions, manufacturer’s field service reports, samples, operation and maintenance manuals, and other miscellaneous work-related submittals. These submittals are required to amplify, expand, and coordinate other information contained in the contract.

1.2 SUBMITTAL PROCEDURE

A. Definition: For the purposes of this section, the term “Contractor” denotes the prime contractor.

B. Listing: Contained in the specification is a summarized listing of item submittals requiring approval for the work. The listing is included for the convenience of users of the contract documents.

C. Risk: Do not proceed with the part of the work covered by an item submittal including purchasing, fabricating, and delivering until approval is received. Machinery, equipment, material, and articles that do not have the required approval shall be installed or used at the risk of subsequent rejection. Any fabrication or other work performed in advance of the receipt of accepted item submittals and approvals shall be entirely at the Contractor’s risk and expense.

D. Transmittal Timing: Coordinate the preparation and processing of item submittals with the performance of the work. Prepare and transmit each item submittal to the Contracting Officer sufficiently in advance of the performance of related work and other applicable activities. Transmit related item submittals for the same unit of work so that processing will not be delayed by the Government's need to review submittals concurrently for coordination. No delay damages or time extensions will be allowed for time lost in late submittals.

E. Content: Each submittal shall be complete and in sufficient detail to allow ready determination of compliance with contract requirements. All submittals which are generic and list more information than is specifically required shall be marked to identify required information. Complete AF Form 3000 and attach as cover sheet for each submittal. Contractor may include multiple item numbers on an AF Form 3000.

Appendix A-2

F. Language: All item submittals shall be written in English, including documents, notes on drawings, sketches, and/or samples, calculations, manuals, and all other instances of written text and communication.

G. Units: All item submittals shall be marked or show dimensions and values in the same units as specified in the contract documents.

H. Review Time: Allow sufficient time so that contract performance will not be delayed as a result of the time required to properly process submittals, including time for re-submittals, if necessary. Allow 14 calendar days for initial Government processing of each submittal. No extension of time will be authorized because of the Contractor's failure to transmit submittals to the Government sufficiently in advance of the work.

I. Contractor Certification: All submittals shall be carefully reviewed by an authorized representative of the Contractor prior to submission to the Government. Each submittal shall be dated, signed, and certified by the Contractor as being correct and in strict conformance with the contract documents. No consideration for review by the Government of any Contractor’s submittal will be made for any items which have not been so certified by the Contractor. All noncertified submittals will be returned to the Contractor without action taken by the Government, and any delays caused thereby shall be the total responsibility of the Contractor.

J. Deviations: Should any item submittals required by the contract documents show deviations from the contract requirement, the Contractor shall make specific mention of such deviations in the letter of transmittal, including stating cost effects, and product and system limitations which may adversely affect the work, in order that if acceptable, suitable action may be taken for proper adjustment of the contract; otherwise the Contractor will not be relieved of the responsibility for executing the work in accordance with the contract documents and the approved submittals.

Contractor shall clearly mark the proposed variation in all documentation and specifically point out deviations from contract requirements in transmittal letters. Failure to point out deviations may result in the Government requiring rejection and removal of such work at no additional cost to the Government. Deviations from contract requirements require Government approval and will only be considered when advantageous to the Government. When proposing deviations, deliver written request to the Contracting Officer, with documentation of the nature and features of the deviation and why the deviation is desirable and beneficial to the Government. If lower cost is a benefit, include an estimate of the cost savings. In addition to documentation required for deviation, include the submittal information required for the item. Allow an additional 14 calendar days beyond normal submittal review period for consideration by the Government of submittals with deviations.

Appendix A-3

K. Approved Submittals: The part of the work covered by the approved item submittal may proceed provided it complies with the requirements of the contract documents. Final acceptance will depend upon that compliance.

The term “Approved” shall only indicate that there is no exception taken to the submittal. Approval of the item submittal shall not be construed as a complete check, and indicates only that the general method or other information appears to meet the contract requirements. Approval does not relieve the Contractor of the responsibility for any error which may exist.

After item submittals have been approved by the Contracting Officer, no resubmittal for the purpose of substituting materials or equipment, or changes to any other information will be considered unless accompanied by an explanation of why a substitution or change is necessary.

L. Disapproved Submittals: Contractor shall correct disapproved item submittals and resubmit for approval within timeframe noted. If no date is given, Contractor shall submit corrected submittal within 14 calendar days.

If the Contractor considers any correction or notation on the returned submittal to constitute a change to the contract drawings, specification, or statement of work the Contractor shall notify the Contracting Officer.

M. Responsibility: The Government’s review of Contractor submittals shall not relieve the Contractor of the entire responsibility for the correctness of details and dimensions and conformance to the specifications. The Contractor shall assume all responsibility and risk for any mistakes and/or costs due to any errors in submittals.

N. Inconsistencies: If a conflict or inconsistency arises between an approved item submittal and the contract documents, the contract documents shall govern.

1.3 SPECIFIC SUBMITTAL DESCRIPTIONS AND REQUIREMENTS: Submittal requirements for individual units of work are specified in the specification. Except as otherwise indicated in the specification, comply with the following requirements for each type of submittal.

A. Shop Drawings: These are technical drawings and data specially prepared for this contract including fabrication and installation drawings, setting and seaming diagrams, and coordination drawings (for use on-site). Shop drawings include drawings, diagrams and schedules specifically prepared to illustrate some portion of the work, diagrams and instructions from a manufacturer or fabricator for use in producing the product and as aids to the Contractor for integrating the product or system into the project, or drawings prepared by or for the Contractor to show how multiple systems and interdisciplinary work will be coordinated. Information required on shop drawings includes dimensions, identification of specific products and materials which are included in the work, compliance with specified standards, and notations of coordination requirements with other work.

Appendix A-4

Provide special notations of dimensions that have been established by field measurements. Highlight, encircle, or otherwise indicate deviations from the contract documents on the shop drawings. Furnish one hard copy and one electronic copy.

B. Samples: These are physical examples of work to be used for independent inspection and testing. Samples include fabricated or unfabricated physical examples of materials, equipment or workmanship that illustrate functional and aesthetic characteristics of a material or product and establish standards by which the work can be judged, and field samples and mock-ups constructed on the project site to establish standards by which the ensuring work can be judged. This includes assemblies or portions of assemblies which are to be incorporated into the project and those which will be removed at conclusion of the work.

C. Test Plans and Reports: Test plans shall include planned testing, including a description of the test, equipment and supplies needed, and step-by-step notation of test activities and tasks. Test reports include reports signed by an authorized official of a testing laboratory that a material, product or system identical to the material, product or system to be provided has been tested in accordance with the specified requirements.

Testing shall have been within three years of date of contract award for the project. Reports also include findings of tests required to be performed by the Contractor on an actual portion of the work or prototype prepared for the project before shipment to the job site, findings of tests made at the job site or on a sample taken from the job site, investigation reports, daily logs and checklists, and final acceptance test and operational test procedures. Furnish three hard copies and one electronic copy of each such report required.

D. Manufacturer’s Field Reports: Documentation of the testing and verification actions taken by a manufacturer’s representative at the job site, in the vicinity of the job site, or on a sample taken from the job site, on a portion of the work, during or after installation, to confirm compliance with the manufacturer’s standards or instructions. The documentation shall be signed by an authorized official of a testing laboratory or agency and shall state the test results, and indicate whether the material, product, or system has passed or failed the test. Furnish three hard copies and one electronic copy.

E. Record (As-Built) Drawings: Record drawings showing final configuration of work accomplished. Show all changes, additions, and deviations from the original contract drawings and documentation. If no changes occur, furnish certification to that effect. Drawings may be redlined hardcopies or electronic drawings, and shall accurately show as-built conditions during the progress of the job. If electronic, furnish drawings on a CD-ROM, in AutoCAD 2005 format or later, including every associated component file

Appendix A-5 of the drawings, including raster images, jpeg, tiff, Excel, and any related items required to view, modify, or manipulate the electronic files. Submit to the Contracting Officer for approval prior to applying for final payment.

F. Miscellaneous Submittals: These are work-related, non-administrative submittals that do not fit in the previous categories, including the following:

1. Qualification certificates. Furnish one hard copy and one electronic copy.

2. Warranties.

END OF SPECIFICATION

Drawing Approved Electronically

07/01/2011

RELEASED FOR EXECUTION

HAMPTON-TA

NOT AEDC STINFO

Drawing Approved Electronically

03/30/2011

RELEASED FOR EXECUTION