Statement_of_Work_Revision_I.pdf

H7WC11 Horizontal Furnaces 18 August 2017

STATEMENT OF WORK

Purchase Description for the Procurement of (2) two Stainless Brazing Vacuum Furnace

1.1 SCOPE

1.2 Scope. This purchase description establishes the minimum requirements for the design, operation, construction, turnkey installation and acceptance procedures for (2) two Horizontal Loading brazing vacuum furnace with equipment and accessories as described herein as well as the removal/relocation of the two furnaces that presently occupy the installation site. The equipment shall include, but not limited to, piping, pumps, valves, regulators, siting work, etc. The equipment shall be new and unused, capable of performing its intended function in accordance with the operation and performance requirements specified herein. The equipment shall be complete, so that when connected to the utilities identified herein, it can be used for any function for which it is designed and constructed. The equipment shall be one of the manufacturer's current production models which, on the date this solicitation is issued, has been designed, engineered and sold, or is being offered for sale through advertisements or manufacturer's published catalogs or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein

2.1 APPLICABLE DOCUMENTS

2.2 General. 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 must meet all specified requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed.

2.3 Government documents.

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

Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

STANDARDS - FEDERAL

FED-STD-H28A - Screw Tread Standards for Federal Service (1994 edition)

U.S DEPARTMENT OF LABOR, OCCUPATIONAL SAFETY AND

HEALTH ADMINISTRATION (OSHA)

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

CFR 1910 (2012 edition)

(Application for copies should be addressed to the OSHA Publications

Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

DEPARTMENT OF DEFENSE

ITEM UNIQUE IDENTIFICATION MARKING (IUID)

MIL-STD-130N - Identification Marking of U.S. Military Property (2012 edition)

(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)

2.3.2 Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

2.4 Non Government Publications. The following documents form a part of this document to the extent herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

(NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 79: Electrical Standard for Industrial Machinery (2012 edition)

NFPA 70: National Electrical Code (2014edition)

NFPA 86D: Standard for Industrial Furnaces Using Vacuum as an

Atmosphere (1999 edition)

NFPA 101: Life Safety Code (2012 edition)

(Applications for copies should be addressed to the National Fire Protection

Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA MG-1 - Motors and Generators Errata (2011 edition).

NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum) (2008 edition)

NEMA ICS 1 - Industrial Control and Systems General Requirements, (January 2000).

NEMA ICS 6 - Enclosures for Industrial Control and Systems, (2011 revision).

NEMA FB 1 - Fittings, Cast Metal Boxes, and Conduit Bodies for Conduit, Electrical

Metallic Tubing, and Cable, (2012 edition).

(Application for copies should be addressed to National Electrical Manufactures

Association, 1300 N. 17th Street; Suite 1847, Rosslyn, Va., 22209, Phone 703-841- 3200/325, Fax 703-841-3300/335)

SOCIETY OF AUTOMOTIVE ENGINEERS

AMS 2750E - Pyrometry (2012 edition)

AMS 2769B - Heat Treatment of Parts in a Vacuum (2009 edition)

AMS 2678A - Furnace Brazing of Parts I a Vacuum Atmosphere (2013 edition)

(Application for copies should be addressed to SAE International, 400 Commonwealth

Drive, Warrendale PA, 15096-0001, Phone 724 776-4841)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

ANSI/ASME - Boiler and Pressure Vessel code, Section VIII, Pressure Vessels, Division

I and Division II

ASME BPVC-VIII Division 1- Rules for Construction of Pressure Vessels Division I

(2013 edition)

(Application for copies should be addressed to the American National Standards Institute, ATTN: Sales Dept., 1430 Broadway, New York, NY 10018-3363.)

AMERICAN SOCIETY FOR TESTING AND MATERIALS

ASTM SI 10- American National Standard for Use of the International System of Units

(SI): The Modern Metric System. (2010 edition)

(Application for copies should be addressed to the ASTM International, ATTN: 100 Barr

Harbor Drive West Conshohocken PA19428-2959 Phone: (610)832-9585 www.astm.org)

American Gear Manufacturers Association (AGMA)

AGMA 2015-1-A01: Accuracy Classification System – tangential measurements for cylindrical gears (2001 replaced 2000-A88)

(Address application for copies to: 500 Montgomery Street, Suite 350, Alexandria, VA

22314-1581 USA)

2.5 Order of Precedence. In the event of a conflict between the text of this specification and the reference cited herein, the text of this specification shall take precedence. Nothing in this specification, however, shall supersede applicable laws and regulations unless a specific exemption has been obtained.

http://www.astm.org/

2.6 Outages: Outages for utility interconnections shall be coordinated with the

Government. and requires three to four week notice.

2.7 Safety: The contractor is advised that natural gas piping is in the work area. The contractor is advised that electric service is in the work area. Fall protection, PPE, and any other safety related material needed shall be provided by the contractor for contract employees. All safety signage in the work area and OSHA regulations shall be strictly followed by the contractor. The contractor’s onsite supervision shall be responsible for ensuring personnel related to this project observe and follow the safety guidelines and properly wear the correct PPE. Hard hats shall be required in the facility, due to the ongoing construction, as well as hearing and eye protection and safety glasses.

2.7.1 Personal Protection Equipment: Contractor shall supply PPE for initial operation setup the table below is for Government personnel, additional PPE needed for the contractor’s personnel shall be provided by the contractor and not be subtracted from the quantities below. PPE shall include but not be limited to, face shields, safety glasses, aprons, gloves, boots, and ear plugs. A list of PPE with possible part numbers or national stock numbers (NSN) is listed in Appendix A, if a different part number or NSN is substituted for the item an equivalence justification shall be provided to the Government for approval, the contractor shall have approval prior to ordering the material.

2.7 Contractor Usage: Electricity and compressed air for power tools will be available for use by the contractor at the work site. The contractor shall provide extension cords and compressed-air extension hoses to connect into the utilities for construction use.

2.8 25% Review: The 25% design review shall take place within 3 week of contract award. This review shall show equipment location (to include foot prints of all major pieces), any roof penetrations needed to be ready prior to installation, and utility drops and placement. This review shall be an onsite visit if contractor has not already been onsite. A Teleconference will be acceptable if contractor has previously been onsite;

contractor shall be responsible for identifying the locations of the major equipment and obstacles that must be addressed. Design may require modifications due to obstacles, constraints or preferences these changes to the design shall be made at no additional expense to the Government. Also, a timeline that shows major milestone dates, such as design reviews, fabrication dates, delivery, installation, training, design reviews, and completion of each system. The Government shall have 3 week to review and respond to the contractor regarding the proposal.

2.8.1 65% Review: This review shall take place within 3 weeks after 25% review is accepted and shall include details about type of equipment specifications, utility requirements, utility drops and placement, air flow calculations, safety equipment locations, SDS ,drawings, and proposed furnace cooling package. This review shall allow the Government to review all applicable documentation to verify compliance with all regulations noted. The Government shall have 3 weeks to review and respond to the contractor regarding the proposal. This review shall be teleconference call; contractor shall be responsible for identifying the locations of the major equipment and obstacles that must be addressed.

2.8.2 100% Review: This review shall take place within 3 weeks after 65% review is accepted to include all details necessary for the Government to verify that all changes have been made to meet the stated intent of this SOW. . The Government shall have 3 weeks to review and respond to the contractor regarding the proposal. This review shall be a teleconference visit; contractor shall be responsible for identifying the locations of the major equipment and obstacles that must be addressed. The contractor shall have two hundred days (200) days to complete the installation of the new equipment. The contractor shall be responsible for placing all equipment and support equipment.

2.9 NOTES

1) Preliminary inspection of the Stainless Brazing Vacuum Furnaces shall be at origin with Final Inspection and Acceptance at destination upon completion of installation at the customer’s facility by the contractor.

2) "Safety Data Sheet (SDS) information shall be provided with the equipment at the time of delivery. This information is required for all liquid, gas, and potentially hazardous material included as part of the equipment, as delivered."

3.1 REQUIREMENTS

3.2 Design. The item offered shall be new and a current commercially available model.

A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures.

Products such as a prototype unit, modified unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The furnace shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair. The furnace shall be of the horizontal loading design and shall vacuum braze Stainless material at full or partial capacity

(capacity is 500 lbs.).

3.2.1 New Developments. The contractor shall identify any new developments that would improve the efficiency, accuracy or productivity of the equipment or would decrease its operating costs. The contractor shall notify the Contracting Officer in order that the new developments may, at the Government's option, be included in the equipment. Reports of such developments shall be addressed to the Contracting Officer.

3.2.2 Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in the inch/pound. All process parameters shall be displayed in Standard units of psig and degrees F in accordance with ASTM SI 10;

(vacuum shall be expressed in units of torr). Non process specific parameters, such as cooling water temperature gages and pressure gages shall be displayed in standard units of psig or degrees Fahrenheit.

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

3.2.4 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.

3.2.4.1 Safety Guarding. Covers, guards, or other safety devices shall be provided. The safety devices shall not interfere with the operation of the furnace. The safety devices shall prevent unintentional contact with the guarded part, and shall be removable to facilitate inspection, maintenance, and repair of the parts. The machine shall be supplied with total machine guarding.

3.2.4.2 Safety Devices. The system shall be equipped with all safety devices required by

29 CFR 1910 (OSHA), NFPA 101 and NFPA-86D. These shall include, but are not limited to, limit switches on automatic movements, overpressure warning, breaker-equipped cabinets, and a red emergency stop button. The emergency stop button shall immediately shut down all electrical current to the 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. 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. A safety door interlock shall be provided to prevent the furnace door from opening above 200 degrees F. The operational sound level of the furnace system shall not exceed 80 dB on the A scale at a distance of three feet at the periphery of the system.

3.2.4.3 Environmental Protection & Safety: The Contractor shall be knowledgeable of and comply with all applicable federal, state and local laws, regulations, instructions and requirements regarding environmental protection and occupational safety and health. The

Contractor shall comply with any laws, instructions or regulation changes during the term of this contract.

Contractors shall be compliant Tinker Air Force Base (TAFB) Supplement to Air Force

Instruction (AFI) 32-7086, “Hazardous Materials Management”, Tinker AFB procedures per Tinker Air Force Base Instruction (TAFBI) 32-7004, “Hazardous Waste

Management”, and Complex procedures per Oklahoma City Air Logistics Complex (OC-

ALC) Sup to AFI 32-7086, “Hazardous Material Management” and OC-ALCI 32-101

“Air Quality Record Keeping Procedure”. Publications are available digitally on e-

Publishing website at www.e-publishing.af.mil for downloading or ordering.

Hazardous Material (HAZMAT): If no HAZMAT will be brought on base or used in performance on this contract, the contractor shall certify “No HAZMAT will be brought on base” or “No HAZMAT Usage” by official correspondence. This certification shall be provided to the COR within ten (10) days after award. Upon COR receipt of the certification, the requirements of this section no longer apply. Appropriate penalties for the contractor, or administrative and disciplinary action for the later shall be assessed if found in violation of above certification.

http://www.e-publishing.af.mil/

The Contractor shall not store chemicals or hazardous material (HAZMAT) on Tinker

AFB. Contractors shall be compliant with HAZMAT management procedures per

Oklahoma City Air Logistics Complex (OC-ALC) Supplement to AFI 32-7086, “Hazardous Materials Management”. The Contractor shall maintain a log of all

HAZMAT that is used on base. This usage log shall be provided to the COR monthly, the last business day of each month, or when the required work is completed. The COR will forward the records to the Unit Environmental Coordinator (UEC) no later than the fourth (4th) day of the following month or the first (1st) subsequent business day.

Safety Data Sheet (SDS) and Labeling: Upon COR receipt of the “No HAZMAT

Usage” certification, the requirements of this section no longer apply.

The Contractor shall not transport, ship or use any chemical, material or substance used in the performance of this PWS on Tinker AFB before written approval is provided by 72

ABW/CEIE, Natural Infrastructure Management (Environmental Compliance). The

Contractor shall submit to the COR, ten (10) calendar days after contract award date all

Safety Data Sheets (SDSs) and a completed OC-ALC Form 152, SDS Information

Sheet. The Contractor shall receive approval from the COR prior to shipping any chemical, material or substance to Tinker AFB. A copy of the manufacturer SDS shall accompany the shipment. Contractor shall comply with the effective dates for SDS requirements IAW the Occupational Safety and Health Administrations (OSHA)

Hazardous Communication Standard, Title 29, Code of Federal Regulation (CFR) Part

1910.1200. The Contractor shall ensure containers of hazardous chemicals are labeled with the following information, prior to shipping to Tinker AFB IAW OSHA Hazardous

Communication Standard, Title 29, CFR Part 1910.1200 (2012): product identifier; signal word; hazard statement(s); precautionary statement(s); pictogram(s); and name, address and telephone number of the chemical manufacturer, importer, or other responsible party.

The COR will forward all SDS submittals to 72 ABW/CEIE for approval. A current manufacturer SDS shall be submitted to the COR if the Contractor changes manufacturer or vendor for any chemicals that were prior approved. The Contractor shall maintain copies of manufacturer SDSs for all chemicals and SDSs shall be readily accessible at all times by Contractor personnel as well as government employees.

Hazardous Waste: If no HAZWASTE will be generated during performance of this contract, the contractor shall certify “NO Hazardous Waste Generation” by official correspondence. This certification shall be provided to the COR within ten (10) days after award. Upon COR receipt of the “No Hazardous Waste Generation” certification, the requirements of this section no longer apply. Appropriate penalties for the contractor, or administrative and disciplinary action for the later shall be assessed if found in violation of above certification.

The Contractor shall dispose of contaminated solid waste, spent or processed chemical solutions, used rags and hazardous waste in government furnished waste containers located in the shop or area the work is being performed. The Contractor shall notify the

COR if the required waste containers are not available on site.

Discharges: Any discharges into Tinker’s industrial waste treatment plant (IWTP) or sanitary sewer shall be approved and done IAW Tinker Industrial Waste Water Discharge

Permit as instructed by 72 ABW/CEIE, Natural Infrastructure Management

(Environmental Compliance). Notice of intent documentation shall be provided to the

COR within ten (10) days after award. The COR will submit the required notice of intent documentation to the UEC for 72 ABW/CEIE approval. The Contractor shall not discharge into IWTP and sanitary sewer prior to approval issued by 72 ABW/CEIE. The

Contractor shall maintain records of written approval issued by 72 ABW/CEIE for discharges into IWTP and sanitary sewer.

Off-Site Discharges: For discharges outside of Tinker AFB, the Contractor shall ensure waste water discharges, that may contain pollutants resulting from any contracted service, go to a state or federal permitted treatment facility such as a municipal Publicly Owned

Treatment Works (POTW). The Contractor shall provide official correspondence ten

(10) calendar days after contract award date to the COR from the POTW that states the

POTW is permitted for all pollutants that the Contractor may discharge during the contracted service.

Spills: Upon occurrence of any spill that could enter the storm system or cause any harmful environment effects, the Contractor shall immediately call 911 to report the incident. When possible, the Contractor shall use a base telephone to receive help from

Tinker AFB 911. If using a cell phone, the Contractor shall request Tinker AFB 911.

The Contractor shall immediately report all environmental violations to the COR and

UEC. The Contractor shall provide five (5) copies of a typed or written report about the incident within four (4) clock hours as follows:

One (1) copy to CO, two (2) copies to the COR, a copy for UEC and one (1) copy for record. The format of the report shall be left up to the Contractor, but the report shall contain the following information:

1.) Name and contact number of person reporting the spill

2.) Date and time of incident

3.) Location and source of spill

4.) Substance or pollutant spilled

5.) Amount spilled and rate of discharge

6.) Any damages or injuries involved

7.) Extent of area impacted

8.) Potential hazards

9.) Actions taken

10.) Organizations contacted

11.) Remarks Section - that addresses the cause of the spill (e.g. human error, equipment, etc.) and whether 911 was called and which agencies responded.

Environmental Training: Upon COR receipt of the “No Hazardous Waste Generation” certification, the requirements of this section no longer apply.

Contractor personnel performing duties in the service of this PWS shall have training that acquaints the person with the details of Resource Conservation Recovery Act (RCRA) regulations in 40 CFR 260 through 279; applicable State Laws and regulations; DoD, Air

Force and local requirements. This training can be obtained through creditable training institutions or companies. All training shall be approved by 72 ABW/CEIE, Natural

Infrastructure Management (Environmental Compliance). RCRA training is available at http://www.natlenvtrainers.com/RCRA-hazardous-waste.htm;

http://www.skillsoft.com/catalog/detail.asp?CourseCode=esh_sah_a34_sh_enus000000 and http://www.lion.com/Storing-Hazardous-Waste-for-LQGs at the Contractor’s expense. Prior to obtaining training, the Contractor shall provide the name of the training institution or company and course description to the COR for approval within ten (10) calendar days after contract award date. Once written approval is received from the

COR, the Contractor shall provide the environmental training certificates for employees performing duties in the service of this PWS to the COR, within thirty (30) calendar days after contract award date. In addition to the required environmental training, Contractors shall be compliant with Tinker AFB procedures per TAFBI 32-7004, “Hazardous Waste

Management

3.1.5 Audible Noise Level. Audible noise emitted by the equipment shall not exceed

80 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 80 dB requirements.

3.1.6 Mercury Restriction. The machine shall not contain mercury or mercury compounds nor be exposed to free mercury during manufacture.

3.1.7 Asbestos Restriction. Asbestos and materials containing asbestos shall not be used on or in the machine.

3.1.8 Lead. Lead and materials containing lead shall not be used on or in the machine except for the electronic components as required.

3.1.9 Use of Polychlorinated Biphenyl (PCB). The use of polychlorinated biphenyl

(PCB) on or in the equipment is prohibited.

3.1.10 Lubrication. Means shall be provided to ensure adequate lubrication for all moving parts for a minimum of 24 hours. Recirculating lubrication systems shall include a filter that can be cleaned or replaced. Means shall be provided to indicate a low oil condition. Shall a low oil condition occur the machine shall enter an emergency stop condition upon completion of the current operation and all oil holes, grease fittings, and filler caps shall be accessible. All oil reservoirs shall have drains and sight gages.

3.1.11 Interchangeability. 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 be interchangeable with domestically supplied components or be readily available from a domestic source.

http://www.natlenvtrainers.com/RCRA-hazardous-waste.htm%3B http://www.skillsoft.com/catalog/detail.asp?CourseCode=esh_sah_a34_sh_enus000000 http://www.skillsoft.com/catalog/detail.asp?CourseCode=esh_sah_a34_sh_enus000000 http://www.lion.com/Storing-Hazardous-Waste-for-LQGs

3.1.12 Equipment Protection. The contractors shall provide the short circuit protection for auxiliary controls, instruments, relays, and sensing devices, etc. All electric motors of

1/4 horsepower and larger shall be provided with short circuit and thermal trip overload protection. Motor sizes shall be such that the driven load shall not exceed the continuous duty rating of the motor. Solid stale reduced voltage (soft start) motor starters shall be provided for poly-phase motors 25 horsepower or larger.

3.2 Construction. The machine shall be constructed of parts that are new, without defects and free of repairs. The equipment structure shall be capable of withstanding all forces encountered during operation of the machine to its maximum rating and capacity without either permanent distortion or distortion affecting tolerances. Construction shall be in accordance with ASME BPVC-VIII shall be free from any characteristic or defect that shall prevent the furnace from passing any of the examinations and tests specified in

Section 4.0.

3.2.1 Casting and Forging. All castings and forging shall be free of defects, scale and mismatching. No process such as peening, plugging or filling with solder or paste shall be used for reclaiming any defective parts without the prior written consent of the contracting officer.

3.2.2 Fastening Devices. All screws, pins, bolts and other fasteners shall be installed in a manner that prevents change in tightness. Those subject to removal or adjustment shall not be swaged, peened, staked or otherwise permanently installed. All fastening devices shall be tightened to torque limits as established by the manufacturer’s standard for tightening to preclude loosening by normal operation or vibration.

3.2.3 Threads. All threaded parts, either US or SI, used on the machine and its related attachments and accessories shall conform to FED-STD-H28A and the applicable

"Detailed Standard" section referenced therein.

3.2.4 Gears. All gears of axis drive trains shall conform to or exceed all provisions of

AGMA 2015-1-A01 grade A5. The gears shall be of proper width and size to transmit full-rated torque and horsepower without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel. Working surface hardness shall be not less than Rockwell 48 C scale.

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

All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

3.2.6 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.

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

3.2.8 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.

3.3 Components. The vacuum brazing furnace shall be a complete horizontal, cold wall, front loading vacuum heat treat furnace system. It shall be electrically heated. The system shall consist of, but not limited to, the following: Chamber Assembly, Plenum

(Hot Zone) with hearth, Vacuum System, Power Supply, Water Cooling System, Thermocouples, and Controls and Gauges. The contractor shall furnish all equipment normally considered standard for the machine, whether specifically called for in this purchase description, or not. The furnace chamber, end, and door shall meet the requirements of the ASME Boiler and Pressure Vessel Code, Section VIII, Pressure

Vessels, Division 1. Formal ASME approval and certification shall not be required. The components and operation of the furnace shall conform to the requirements of NFPA

86D.

3.3.1 Chamber Assembly. The furnace chamber shall be water-cooled. The outer furnace surface temperature shall not be higher than 140F. The water system shall have a drain valve(s) and shall be designed to prevent corrosion and erosion of components. The horizontal vacuum chamber shall be heavy, double walled steel to allow full water-cooling including the door and rear section. The inner shell and all structural material exposed to the vacuum environment shall be constructed of material that shall not oxidize, or constructed of materials that have been plated or coated to prevent oxidation under all furnace operating temperatures, atmosphere, and vacuum pressures specified herein.

3.3.1.1 Furnace Chamber Ports. The vacuum chamber shall contain all necessary ports for the high vacuum pumping system, power terminal entries and furnace over temperature and control thermocouples. These requirements are further specified as follows:

a. The furnace control thermocouple and the over-temperature thermocouple shall be in separate ports with vacuum-tight glands and adequate extension wire to the control cabinet. Review section 3.3.5 for additional survey/calibration thermocouple port requirements. These thermocouples shall be type “S”.

b. All instrument or sensor connections on the vacuum chamber shall have Leybold-

Heraeus KF Type vacuum fittings or equivalent (Contractor shall provide specifications and justification to prove equivalency, the Government reserves the right to determine if the substitute product is equivalent).

c. 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.

d. The Vacuum chamber shall have an additional ISO KF vacuum port accessible at ground level. The KF port will support connection of a Residual Gas Analyzer

(RGA) and shall include any KF type fittings necessary to support intermittent connection of same

3.3.1.2 Vacuum Chamber Door. A double wall construction forming a water jacket shall also be utilized on the door. The inner and outer walls shall be constructed out of mild steel. The outer Door temperature shall not be higher than 140F. The door will be of an autoclave type design with a rotating outer ring type door locking systems to lock the doors for backfill pressure of up to 15 PSIG (2 Bar Absolute). The door will be manual opening/closing and feature standard Buna-N type O-rings to form the seal.

3.3.1.3 Vacuum Chamber Water Cooling Lines, All exit cooling water lines from the furnace shall be positively identified as to their furnace source at the point where the empty, or converge into a return collector or manifold.

3.3.2 Type “K” Thermocouple. The contractor shall provide (12) new type “K”

Inconel sheathed thermocouples shall be provided to monitor work load temperature during the process cycle. Each thermocouple shall be 120” long and be provided with a quick disconnect male plug and female jacks.

3.3.3 Workload Thermocouple Port. The workload thermocouple port(s) shall support a minimum of 12 each type K. 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) 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. A survey rack with the ability to hold ten (10) thermocouples shall be provided.

3.3.4 Survey Thermocouple Port. A survey thermocouple port shall support a minimum of 12 each type K thermocouples. The survey thermocouple signals shall be routed through sealed feed troughs rated for the applicable temperature and vacuum service. Thermocouple jack panels (12 type K with standard 2 pin connectors) 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.

3.3.5 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 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. Provide twelve (12) compensated extension wires with female jack from the feed-through ports to the control cabinet.

3.3.6 Cooling The furnace shall have argon gas cooling capability to cool the workload as well as a water cooling jacket surrounding the hot zone to cool the furnace.

3.3.6.1 Gas Cooling System. The furnace system shall be of adequate capacity and shall include all equipment necessary to provide 30 degree per minute gas cooling capability to the furnace workload (300 lb gross). The quench system shall be a closed loop, re-circulating argon gas cooling system complete with a blower and motor, heat exchanger, and internal distribution nozzles for fast, uniform 360 degree cooling of the workload.

3.3.6.2 Gas Cooling System Configuration The blower and heat exchanger units shall be internally or externally mounted. The contractor must provide provisions to prevent cooling water leakage from entering the furnace chamber. The contractor must provide information on potential failures of internally mounted blowers and heat exchangers.

3.3.6.3 Gas Cooling Control. A variable frequency drive 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.

3.3.6.4 Reservoir Gas Tank The contractor shall provide two ASME coded argon gas backfill reservoir tank(s) shall be provided for rapid gas backfill. The tank(s) shall have sufficient pressure to meet the specifications of this statement of work. Pressure vessels shall be certified. The tank shall be vertically mounted and secured to the floor. The tank shall include a pressure relief valve vented to atmosphere, (Roughing pump vent line can be used) pressure gauge, and copper brazed joint lines. The tank shall be hydrostatic tested and visual inspection performed. The compressed argon gas line shall be regulated to a higher pressure than required at point of use, approximately 125psi. The tank shall be anchored to the cement floor IAW the manufactures specifications.

3.3.6.5 Hygrometer/Dew Point Recorder. The furnace shall be equipped with a hygrometer to determine the dew point of the argon entering the furnace. The sensor shall be mounted on the main argon line immediately exiting the argon accumulator tank.

The copper tubing shall be sized larger on the output side of the sensor to encourage flow. Dew point shall be displayed on the control panel in degrees Fahrenheit.

3.3.6.7 Furnace Cooling Water Assembly. The cooling water system shall have a large water manifold system to optimize water flow in each circuit with valves in critical areas.

All water lines shall be identified. The cooling water lines shall be designed for connection to an existing frame and plate heat exchanger (see attachment A) water cooling system. The system shall have water pressure safety relief valves on front cover and vacuum vessel to protect against over-pressurization. The system shall have water throttling ball valves to control flow to the heat exchanger, diffusion pump, mechanical pump, variable reactance transformer (VRT), main vessel and front door. The furnace vessel shall be equipped with a pneumatic valve to shut-off water flow once the furnace load temperature reaches 150F (66C) to help prevent condensation build-up on the vessel walls and hot zone. The main vacuum chamber shall be equipped with an over-pressure safety relief valve.

3.3.6.8 Furnace Cooling Water Filters. The contractor shall provide and install a dual inlet water screen filtration system for the cooling water system. The filters shall be in parallel and include the necessary valves and piping to allow for cleaning of either screen/filter without shutting off the water. The filters/screen shall be of .060” minimum mesh stainless steel screening.

3.3.7 Heating elements. The heating elements shall be fabricated of Graphite or molybdenum arranged radially around the circumference of the work zone in not less than three individual control zones (includes heating elements on front door and back wall if included in design). Each zone shall include necessary power trimming devices to provide a 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 heating elements shall be located far enough away from the work envelope so as not to allow the work grid to be overheated or hit while loading the components into the furnace.

3.3.8 Hearth Design. The furnace hearth support shall be constructed of graphite or molybdenum support pins and rails and shall include one work grid/surface. The hearth shall provide a stable flat support for an evenly distributed load of at least 500 pounds at

2200 F. Work support rails shall be top slotted to all for molybdenum rod inserts.

3.3.8.1 Work Grid: A graphite work surface shall be supplied which will be 1 inch Thick and 2 inch diameter holes with 3 inch center to center enough to sufficiently cover hot work area to hold parts.

3.3.8.2 Survey Rack: One molybdenum survey rack of sufficient size and configuration capable of service in conditions up to 2400degF and 5x10-6 torr vacuum shall be provided to support measurement of hot zone uniformity. The survey rack shall have TC wells positioned in accordance with AMS 2750E requirements.

3.3.9 Vacuum System. The furnace shall be provided with an automatically operated vacuum system. The system shall consist of the necessary pumps, manifolds, valves, traps, controls, gauges, and piping to provide a constant operating vacuum pressure of 5 x

10-5 torr. The system shall be provided with a pneumatically actuated high vacuum valve that shall automatically close in case of power failure. The vacuum system shall be designed to pull a 5 x 10-5 torr vacuum consistently in 30 minutes maximum with a full load (200lbs).

3.3.9.1 Vacuum System Valves. The furnace vacuum system shall have all of the necessary 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 (for main or weekend shut down) shall require the insertion of a key (or optional password protected

"soft" key) with the following pumps:

3.3.9.2 Diffusion Pump. An adequate diameter high efficiency Varian high-speed vacuum oil diffusion pump shall be provided to meet vacuum requirements in Section

3.3.1. 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 a sufficient quantity of vacuum oil as required for this diffusion pump. Provide suitable means to prevent hard starts and stops to diffusion pump.

3.3.9.3 Mechanical Roughing Pump and Booster Pump. The pumps shall meet the vacuum requirements of Section 3.3.1. Contractor will use appropriately sized Stokes pumps or equivalent as stokes is industry standard. Contractor must provide model numbers of the pumps they intend to use with evidence of equivalence. The pumps shall be put in series and shall be equipped with an oil mist separator and roof vent exhaust connections. Contractor responsible for connecting exhaust to existing roof penetrations.

These pumps shall be mounted in a "drip pan". All belt covers shall be vented or slotted to dissipate heat buildup. The venting requirements shall be identified in the 25% design review.

3.3.9.4 Mechanical Holding Pump.

The mechanical holding pump shall be sized to meet the vacuum requirements in Section

3.3.1 and equipped with an oil mist separator and roof vent exhaust connection. This pump shall be mounted in a "drip pan".

3.3.9.5 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

MMI).

3.3.10 Heat Exchanger. The government shall supply a plate and frame type heat exchanger which connects to the building chilled water lines. The current system is designed to meet the chilled water requirements for the requirements herein. The design has one water supply to the furnace and one water supply from the furnace, which hook to the plate and frame heat exchanger. The placement of the frame and plate is shown in

(Attachment A). Contractor shall be responsible for all installation, of piping and valves to and from heat exchanger; the current system uses the government’s chilled water system as a heat dissipater of the closed loop furnace system and has a control system to keep the water to the furnace and a set temperature. The heat exchanger includes an inert gas backup pump switch that will maintain water flow in case of power failure. The heat exchanger includes a backup pump in case of primary pump failure.

3.3.11 Controls and Gauges. The furnace shall be equipped with but not limited to the following controls and gauges. All controls shall conform to the requirements of NEMA

ICS 1.

3.3.12 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 shall be provided to start or turn-off diffusion pump heaters (or optionally provided via touch screen selection). The panel shall provide for either semi-flush mounts or flush mounts for all instruments.

3.3.13 Furnace Controls. The contractor shall provide data/literature of the set point programmer and programmable logic control1er design; customer references shall be provided with the proposal. The furnace set point programmer and programmable logic controller shall be configured with sufficient I/O 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

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 shall be provided to start or turn-off diffusion pump heaters (or optionally provided via touch screen selection). The panel shall provide for either semi-flush mounts or flush mounts for all instruments.

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

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

Honeywell UDC 1200 (configured for limit control) or equivalent (Contractor shall provide specifications and justification to prove equivalency, the Government reserves the right to determine if the substitute product is equivalent). 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 must 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 shall be provided for the exclusive use of this instrument. Should the over-temperature control point be exceeded an audible alarm shall sound.

3.3.16 Vacuum Instrumentation. Vacuum control and indication shall be provided by utilizing one of the following two options:

a. Panel mounted Televac, Seybold CM31, or equivalent vacuum gauge controller.

b. MMI display of vacuum parameters utilizing contractor’s standard instruments/controllers.

3.3.17 Vacuum Sensors. Vacuum sensors shall be installed and shall consist of:

a. Pirani sensors for a range of 1000 to 10-4 torr (Televac or equivalent

(Contractor shall provide specifications and justification to prove equivalency, the Government reserves the right to determine if the substitute product is equivalent)).

b. Cold-cathode ionization sensors for a range of 10-2 to 10-7 torr (Leybold model PR 35 or equivalent (Contractor shall provide specifications and justification to prove equivalency, the Government reserves the right to determine if the substitute product is equivalent).

c. A mechanical diaphragm pressure gauge (with compound range of 0-

30”Hg Vac – 15 PSIG)

d. Contractors standard sensor for indicating and recording pressures for atmospheric to 2 Bar.

3.3.18 Data Recorder. A paperless Data recorder will be provided by the Government to record vacuum, control thermocouple temperature, and work survey thermocouple temperature. The data recorder shall be removed by contractor from existing furnace and installed and configured in the furnaces for the connectivity requirements of paragraph

3.3.20 and 3.3.20 as necessary.

3.3.18.1 Uninteruptable Power Supply (UPS). A UPS shall be provided to supply not less than 10 minutes of emergency power to the controllers and MMI for proper furnace shutdown in the event of a Commercial power failure. The UPS shall provide voltage regulation in order to automatically correct both high and low voltages to within normal range. The UPS shall also provide surge protection to all connected 115VAC equipment.

3.3.19 Man-Machine Interface (MMI).The contractor shall also provide a furnace control system that performs all furnace sequencing and alarm functions and a color touch screen

MMI. This interface shall provide:

a. All of the control and interface features as specified in paragraphs 3.3.19.1, 3.3.20, and 3.3.20.1

b. Any program features or tools that the contractor typically provides with this option.

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

3.3.19.1 MMI Screens (Displays). Operator access to furnace control, monitoring, recipes

(creation/modification/retrieval), alarms, history/reports, variable entry (for routine parameters), and etc., shall be through the use of displays, menus, and windows. These interactive displays shall include, as a minimum, the following:

a. Security. A display menu for log on/off, password and operator ID verification, and other options or features that the contractor normally supplies.

b. Furnace graphics. A graphical display of the furnace system illustrating on/off status of pumps, blower, and heating elements; open/closed status of valves; temperature and pressure values of the furnace and pumping system, etc. shall be provided.

c. Process Overview. A display for status of process parameters: program loaded, segment#, soak time, set point, elapsed cycle time, workload thermocouple values, control and over-temp T/C temperatures, furnace pressures, and etc.

d. Process Programming. A display menu for loading, creating, or modifying furnace recipes; setting events and routine parameters, and managing workload thermocouples.

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

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

3.3.20 Software and Programming. The controller shall be programmed and configured to provide all logic control necessary…