Ion Nitride System Specification 20_0317_AK REV B betaSAM.docx

11-18-3424 Rev. A Specification for New Ion Nitride System

# 20-0317-AK

Rev. B

ODR

Watervliet Arsenal Watervliet, New York 12189 3/17/2020

Department of the Army

TACOM

CONTENTS

PARAGRAPH PAGE

5 Preservation and Packaging 22

1. Scope

1.1. Abbreviated Description. The machine tool covered by this specification shall be a Ion Nitride System with a Horizontal Type Ion Nitriding Furnace with a vessel of cold wall construction and shall be configured to process batch loaded work pieces, positioned on a fixture, which is lowered onto an electrically isolated hearth. The batch load will be loaded and removed by battery operated “Walk-Behind” style loader.

2. Applicable Standards and Publications. The documents listed in this section are referred to in sections 3, 4, or 5 of this standard. This section does not include documents cited in other sections of this standard 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, 4, or 5 of this standard, whether or not they are listed in this section. The quality of all work performed and material provided in association with this specification shall meet or exceed the listed industry standards and engineering practices for this type of equipment and its intended function.

2.1. Non-Government Publications. The following documents 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.

AEROSPACE MATERIAL SPECIFICATION (AMS)

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

AEROSPACE RECOMMENDED PRACTICE (ARP)

AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI)

NATIONAL FIRE PROTECTION ASSOCIATION (NFPA)

NFPA 79 Electrical Standard for Industrial Machinery

INTERNATIONAL ORGANIZATION FOR STANDARDIZATION (ISO)

ISO 230-2:2006 NC Positioning Standard Revised

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME)

B5 Machine Tools Components, Elements, Performance, and Equipment

2.2. Clarification. If any ambiguities or discrepancies between this specification and the standards listed in Section 2.1 are discovered by the contractor during the review of this specification prior to submitting an offer, the ambiguities and discrepancies shall be reported to the contracting officer by the contractor before the close of bidding or receipt of proposal. Submission of a proposal or a bid shall be construed as evidence that the examination of this specification has been made. Contractor claims for labor, material, equipment, or difficulties encountered, which could have been discovered during this examination, shall be denied.

3. Requirements.

3.1. General Requirements. The equipment specified in this document shall be a standard product of the manufacturer and shall require either no design changes, or if required, minor design changes to meet the requirements of this specification. Therefore, ownership of the design shall remain with the manufacturer.

3.1.1. Design and Engineering. The equipment specified in this document shall be designed and engineered in accordance with the latest standards, recognized by the Association for Manufacturing Technology and as listed in Section 2.1.

3.1.2. Materials and Components. Materials and Components incorporated in the construction of the equipment specified in this document, shall be free from defects and shall conform to the specifications and standards listed in this document.

3.1.3. Construction. All parts of the equipment specified in this document shall be new, unused and shall be constructed to be capable of withstanding all forces encountered during operation to the equipment’s maximum rated capacity.

3.1.4. Workmanship. Workmanship throughout the equipment specified in this document shall be free from irregularities or defects that could adversely affect performance or durability.

3.1.5. Maintainability. All equipment components offered that are subject to wear, distortion or failure and all parts which require periodic adjustment shall accessible for replacement or adjustment. Instructions for the maintenance and adjustment of these parts shall be clear, concise and definitive.

3.1.6. Interchangeability. All parts offered that bear the same part number shall be interchangeable.

3.1.7. Motors. All motors provided shall be of the type and horsepower rating to meet the specified requirements based on the engineering practices and standards listed in Section 2.1. All motors shall be rated for continuous duty. Motors shall not operate in an overload condition during normal operation of the equipment and shall be equipped with thermal overload protection. Motor starters and controls shall operate at 24 VDC. Motor starters shall provide drop out protection. This means that in the event of power loss, the equipment shall be re-energized only by deliberate action of the operator. Manual or mechanical motor starters are not acceptable. All motors shall be housed in enclosures of the appropriate NEMA type for class and severity of service. All AC unidirectional motor housing shall bear a directional arrow to indicate proper rotation direction when correctly wired. All AC motors rated at 25 horsepower or greater shall be equipped with a “soft start” mechanism which provides for reduced voltage starting. All polyphase AC motors rated at 1 horsepower or greater shall be tested per IEEE Standard 112-Method B and must meet Premium Efficiency requirements per NEMA MG 1-2006 Table 12-12 or IE3 9IEC 60034-30:2008. All motors are to be permanently lubricated and sealed.

3.1.7.1. Motor I.D. Plates. Each motor shall bear an identification plate containing the identity of the manufacturer, model number, serial number, input voltage, amperage, horsepower, phase, frequency, duty cycle, and frame size or mounting identification.

3.1.8. Operator Control Voltage. All electrical controls meant for use by the operator of the machine shall carry 120 volts AC maximum.

3.1.9. Safety and Environmental Requirements. The contractor shall review the environmental requirements documented in Appendix D of this document and comply as required.

3.1.9.1. Protection of Machine Operator. Protection of the machine operator and other personnel shall be accomplished in accordance with the standards listed in Section 2.1.

3.1.9.2. Protection of the Machine. The machine shall be designed and equipped in accordance with the standards listed in Section 2.1 to prevent self-damage in the event of malfunction and ordinary operator negligence.

3.1.9.3. Noise Levels. Noise levels at a distance not exceeding one meter from the nearest point on the machine shall, under no circumstances, exceed a maximum of 85 dba when measured by a calibrated sound level meter set for "A" weighting and slow response. Any shields, baffles, enclosures or other devices required to bring the machine into conformance with this noise level requirement shall be furnished by the contractor. Any such devices shall not interfere with the operation of the machine and shall be designed to preserve the visibility needed for safe operation and ease of maintenance.

3.1.9.4. Ozone Depleting Substances. Section 326 of Public Law 102484 precludes the Dept. of Defense from awarding any contract that directly or indirectly requires the use of a class I ozone depleting substance within the Government specification or standards set forth in the contract. Appendix B is a list of the restricted Class I CFCs and Halons. The equipment specified in this document shall utilize new, functionally equivalent substances or systems that are approved for use by the Environmental Protection Agency (EPA) and have an "Ozone Depletion Potential" (ODP) rating of zero.

3.1.9.4.1. Ozone Depletion Potential (ODP) Definition. The relative capacity of a substance, per unit weight, for destroying the earth's stratospheric ozone layer in comparison with CFC11, CFC12 and CFC 114, each having been assigned an ODP of 1.00.

3.1.9.4.2. Prohibited Substances. Offerors are responsible to obtain and adhere to the most current list of environmentally prohibited substances as of the date of the submission of bids or proposals.

3.1.9.5. Asbestos and Mercury Free Certification. All materials utilized in the system shall be certified as asbestos and mercury free unless substitute materials do not exist. This certification shall be provided prior to machine delivery.

3.1.9.6. Material Safety Data Sheets. The offeror shall provide Watervliet Arsenal with all material safety data sheets at the time of proposal submission.

3.1.9.7. Lead Free and Chromium Free Paint Certification. All paints and primers applied to the system shall be certified as lead free and chromium free. Lead based paint is paint that contains more than six one hundredths of one percent (0.06%) lead by weight. This certification shall be provided prior to machine delivery.

3.1.9.8. PCB Free Certification. To the extent that the machine is charged with lubricant or hydraulic fluids at the contractor's plant for preliminary acceptance inspection, these fluids shall not contain Polychlorinated Biphenyl’s (PCBs). The machine and its equipment shall be certified as PCB free and certification shall be provided prior to machine delivery.

3.1.9.9. Lockout/Tagout Procedures. The manufacturer shall provide the control of hazardous energy (lockout/tagout) per OSHA 29 CFR 1910.147. This information shall be incorporated into the maintenance manual. The control of hazardous energy sources includes but is not limited to electrical, pneumatic, hydraulic, chemical, mechanical, UV, electromagnetic and thermal energy.

3.1.10. Identification Plate. A corrosion resistant metal plate shall be securely attached to the machine in a location visible to the operator's workstation. This plate shall bear, as a minimum, the information called for below, with space at the bottom of the plate for the addition of one line of information to be applied by the government.

Nomenclature Manufacturer's name Model Manufacturer's Serial Number Power Input (voltage, phase, frequency, and full load amps) Government Contract Number Date of Manufacture

3.1.11. Data Plates. All instruction, data, and identification plates and labels attached to this equipment and its controls shall be manufactured of corrosion and oil resistant metal or plastic material. All wording shall be in the English language using plain, bold face lettering. Lettering shall be permanent and have a contrasting background.

3.1.12. Utility Connections. Equipment supplied to the Watervliet Arsenal shall have a single point shut off for each utility supplied to the system. This will be referred to as the “point of first connection”. Each type of energy source shall have only one point of first connection. Each point of first connection shall be clearly labeled on the system and shown in the safety Lockout/Tagout portion of the documentation package. These points shall be located on a stationary component and positioned so that they will not create a hazard to personnel during normal operation of the system. The first connection points shall be accessible from the shop floor without the use of ladders, steps, or stools. Access cannot be hampered by operation of the system.

3.1.13. Utility Connection Labor. Watervliet Arsenal shall only provide labor and materials to connect facility utilities to each point of first connection of the system. The supplier will be responsible for all connections beyond the point of first connection for each utility.

3.1.14. Utility Requirements.

3.1.14.1. Electrical. The WVA power source that the specified equipment will be connected to will be a nominal 480 volts, 3 phase, 60 Hz AC voltage. However, the machine shall be able to operate normally at source voltages ranging from 432 to 504 volts. The WVA power source does not include filters, surge protection, or any peripheral equipment necessary to make the equipment functional.

NOTE: Offeror is to state required power/electrical requirements for offered machine. See Appendix C and complete.

3.1.14.1.1. Electrical Conversion Equipment/Transformers. If DC or reduced AC voltage is required to meet any specified equipment requirement, the conversion and transformation equipment shall be furnished with the machine. All transformers must meet NEMA TP 1-2002 energy efficiency requirements. Equipment which requires a high quality constant power source shall be furnished with the proper isolation and power conditioning equipment for the power service designated in this description

3.1.14.2. Pneumatics/Air. If air is required for any machine operation or function, the machine shall be fully equipped with all required components, fully installed to the point of connection of WVA shop air. Shop air at the Arsenal is 85 psi with above normal moisture and contaminant levels. If higher or lower pressure is required at the machine or a different air flow rate is needed, the machine shall be fully equipped to modify the supply pressure and volume. The machine shall also be equipped to remove the above normal moisture and contaminant levels. Normal moisture is defined as that moisture produced when air at a relative humidity of 75% has been compressed to 85 psig.

3.1.14.2.1. Air Dryers/Filtration. If the offeror determines that on machine air dryers are required to maintain moisture levels the air dryers shall have a regenerative type desiccant or refrigerated compressed air dryer capable of drying air down to 35° F pressure dew point, minimum, from air entering the equipment at 110° F. The air dryer shall supply air at the required standard cubic feet per minute (SCFM) of the equipment. The unit shall purge condensate automatically. In the case of a refrigerated air dryer, the refrigerant used shall not be a Class I ozone depleting substance. The air dryer shall be connected and piped to the equipment by the contractor. All air dryer designs are to be supplied by manufacturers participating in the CAGI Refrigerated Dryer Performance Verification Program and have been tested and rated in accordance with CAGI ADF 100. Power for the refrigerated air dryer unit shall be 110 VAC and shall be wired and powered through the machine electrical system.

NOTE: Common industrial air dryers that are used at the Watervliet Arsenal include the ZEKS HSE and Ingersoll Rand D31NC models.

3.1.15. Lubrication. The machine shall be equipped to provide lubrication to every moving part where lubrication is essential to prevent damage. Manual lubrication methods are permissible for lubrication points not practically served by automatic systems.

3.1.15.1. Lubrication Plate. A lubrication plate shall be permanently fastened to the machine and shall clearly indicate the type and viscosity of lubricant and the service interval for all automatic and manual lubrication reservoirs and fittings. The plate shall include a simple diagram which depicts the physical location of all lubrication points on the machine structure.

3.1.15.2. Lubricants, Hydraulic Fluids, Oils and Coolants. Watervliet Arsenal has established a standardized list of lubricants, hydraulic fluids, oils and coolants. The contractor shall choose the required lubricants, hydraulic fluids, oils and coolants from Appendix “A”, enclosed or where there is a designated equivalent. If a substitute is required, the contractor shall provide at the time of machine delivery, a justification which shall include the manufacturer, type and specification number as well as the reason for the substitution.

3.1.16. Painting. All exterior machine surfaces shall be painted except where bright metal is required for machine function or to otherwise adhere to the requirements of this specification. Paint shall be chromiumfree and leadfree. Quality and manner of application shall afford protection throughout the normal life of the machine. Paint shall be "semigloss", and selected by the Government, from a list of standard colors supplied by the offeror with their proposal. This selection shall be made after contract award. Danger areas shall be painted red and caution areas shall be painted yellow in accordance with OSHA Standard 1910.144. Appropriate warning signs, tags or emblems will be affixed to respective areas of the machine in accordance with OSHA Standard 1910.145.

3.1.17. Machine Hold Down and Leveling. The machine base shall be provided with a mounting hole quantity and location for positive hold down when operating at full rated capacity. In addition, for each hole in the machine base, the contractor shall provide a set of recommended hold down and leveling hardware.

NOTE: All hold down and leveling hardware shall be delivered 30 days prior to the scheduled delivery of the machine.

3.1.18. Gears. All gears used in the machine and its components shall meet or exceed the standards recommended by the American Gear Manufacturers Association for the type and severity of service required.

3.1.19. Technical Data. All data shall be in the English language and shall be furnished in accordance with the quantities, formats and delivery dates below. All data shall be packaged and delivered separately from the machine itself marked to the attention of the Technical POC. The contractor shall provide full documentation in the form of “as built” drawings and manuals. Drawings shall not be generic. A “hardcopy” refers to a reproducible printed, paper copy. An “electronic copy” refers to a document saved on CD. All AutoCAD drawings shall be provided in AutoCAD version 2009, shall be of one-to-one scale, shall be dimensioned in English units, and shall not utilize the color yellow. “On-line” technical data will not be acceptable as the sole means of providing technical data for any of the systems provided. The Government contract number and the Watervliet WV# shall be printed in a conspicuous place on the covers of every manual, on each drawing/schematic, and on all disks/CDs provided.

3.1.19.1. Machine and Equipment Floor Plan. Machine and equipment floor plan AutoCAD drawings shall contain information that indicates the type, magnitude, and connection points of all plant utilities required to operate the machine. The top view AutoCAD drawing shall depict the machine, foundations, all ancillary equipment, and all necessary clearance requirements for normal use and maintenance. This data shall be furnished with offeror’s proposal (One hardcopy and one AutoCAD electronic copy).

3.1.19.2. Catalog of Standard Tooling and Accessories. Catalog shall be furnished 30 days after award of contract. For offers of foreign built machine tools (i.e. machines built outside the United States, its possessions or Canada), the catalog shall set forth U.S. domestic sources of supply. (Two hardcopies)

3.1.19.3. Non-Standard (Special) Tooling and Accessories. To the extent that this specification requires the development of unique tooling and accessories not generally available commercially, a set of drawings and specifications to permit manufacture of such tooling and accessories shall be furnished at the time of machine delivery. (One hardcopy and one AutoCAD electronic copy)

3.1.19.4. Installation Instructions and Drawings. Instructions containing all required to install the equipment shall include a drawing containing the certified dimensioned locations of all equipment mounting/holddown holes. To be furnished 60 days prior to scheduled delivery of the machine. (One hardcopy and one AutoCAD electronic copy)

3.1.19.5. Lubrication Diagram and Instructions. To be delivered to the technical POC at time of machine delivery. (One hardcopy and one AutoCAD electronic copy)

3.1.19.6. Operating Instructions. These instructions shall be provided in separate manuals from other technical data provided. To be delivered upon machine delivery. (Four hardcopies and one electronic copy)

3.1.19.7. Maintenance and Troubleshooting Instructions. To be supplied for all machine and control systems. These instructions shall include the machine’s mechanical assembly drawings. To be delivered at time of machine delivery. (Two hard copies and two electronic copies)

3.1.19.8. Electronic and Hydraulic Schematics. To be considered acceptable, these schematics shall clearly portray all “as built” electrical and hydraulic ties to their respective main systems. To be delivered at time of machine delivery. (One hardcopy and one electronic copy)

NOTE: If, during installation and testing, the actual electrical and hydraulic systems are configured differently than depicted on the schematics, receipt of the revised "as built" schematics shall be a condition of final acceptance.

3.1.19.9. Repair Parts Catalog. This catalog shall encompass every replaceable part in the machine and shall include identification and original equipment manufacturers part numbers and ordering data. Items which can normally be purchased locally may be so indicated provided they are sufficiently described. The repair parts catalog shall include illustrations which clearly locate parts within larger subassemblies. To be delivered at time of machine delivery. (Two hardcopies and one electronic copy)

3.1.19.10. Software Documentation. The offeror shall provide documentation of all system software and ladder logic developed to control and interface with the control/drives with the machine tool. To be delivered 30 days after delivery of the machine. (One hardcopy and one electronic copy) One copy of the system memory backup (S-Ram) shall be provided on compact flash drive at startup of machine.

3.1.20. Training Required. The contractor shall be responsible for providing training of WVA personnel. The type and extent of training shall depend upon whether the machine specified is equipped with numerical control. All instructions and materials, oral or written, shall be in English. "On-Site" means "At Watervliet Arsenal" and "Off-Site" means "a location within the U.S. away from Watervliet Arsenal as determined and arranged for by the contractor". If specialized formal “off-site” training is available, specify on offer, availability and price as an option. The quality of the training shall be such that at the conclusion of the specified training time, each individual within their assigned category shall be capable of repairing or operating the machine to its productive capacity. Training shall be in accordance with the applicable areas of the following schedule:

Hydraulic maintenance (if applicable)

NOTE: For all types of training, the associated technical data (see 3.1.24) shall be on hand at the time of instruction and its use and interpretation shall be covered during the training.

3.1.21. Repair/Replacement Parts and Service. The offeror shall provide parts and service for the contracted equipment within 72 hours of notification of a problem. The offeror shall agree, as part of the contract, to store complete ordering data to include specifications, engineering drawings and other information for the contracted machine tools/parts. This data shall be stored within the U.S. or Canada and in detail to permit successful acquisition of the parts and associated repair service. The offeror shall supply a list of recommended spare machine parts as an option with the offer. Watervliet Arsenal recognizes that it may be hard to fulfill this requirement for major machine components. If the requirement cannot be adhered to, the offeror shall notify Watervliet Arsenal’s POC within two business days and shall provide a delivery schedule to be approved by Watervliet Arsenal’s POC.

3.1.22. Special Tools. If any element of machine operation or maintenance requires the use of specially designed tools, these tools shall be provided with the machine and shall become the property of the Government.

3.1.23. Site Conditions. The machine covered by this specification will be installed in general machine shop space and there will be no environmental conditioning. Temperatures will range from 65° F to 95° F and relative humidity will range from 20% or less to 95%. On any given day, the temperature in the machine shop may change as much as 4° F per hour. These are the conditions under which the machine is expected to perform as specified, and the contractor shall be responsible for supplying what is required to meet the specified performance. The only permissible exception is positioning accuracy for numerically controlled machines. For this performance factor, allowances may be made for the effects of temperature fluctuation.

3.1.24. Machine Installation, Startup and Testing.

3.1.24.1. Work to be performed by the Arsenal.

3.1.24.1.1. Site Designation. Upon receipt of the required installation and foundation drawings (see 3.1.24), Watervliet Arsenal will designate an installation site and outline a general machine location on the shop floor.

3.1.24.1.2. Utilities. Once the machine is installed, positioned and rough leveled by the contractor or their designated rigging crew, Watervliet personnel will run utilities (power and air) to first points of connection on the machine. Watervliet must be provided with sufficient time to accomplish these connections. Sufficient time may be up to 3 working days depending on Watervliet personnel availability. However, if the installation instructions supplied by the contractor are incomplete or insufficiently detailed, installation work will stop and the contractor will be required to dispatch a service engineer. Installation will resume upon their arrival and continue under their guidance.

NOTE: If installation instructions, electrical and hydraulic schematics are not delivered at or before the times specified (see 3.1.24), the Government reserves the right to forestall delivery and/or final acceptance testing of the machine by an amount of time equal to the delay in receipt of instructions, drawings or schematics.

3.1.24.2. Work Performed by the Contractor. This project is classified as a “turn-key” system with the contractor being responsible for all costs and work associated with the installation unless otherwise stated. The Contractor shall be solely responsible for all costs associated with skidding and shipment, rigging, and installation at WVA. Contractor personnel shall adhere to the WVA requirements to wear OSHA approved non-tinted safety glasses with side shields, to wear safety shoes, and to refrain from wearing loose clothing (i.e. “hoodies”) and jewelry while in the manufacturing shop areas. The contractor shall ensure they bring all equipment/material necessary for the installation of the machine.

3.1.24.2.1. Site Preparation. Once an installation site is identified by Watervliet personnel and if required, a foundation is constructed, the contractor or their designated third party shall layout the machine. Please note that the majority of the Watervliet Arsenal’s shop floor is covered with 2.5” thick wood block. The contractor is responsible for the removal of wood block flooring and existing concrete preparation. Contractor shall also be responsible for securing wood block flooring and install any leveling pads necessary for installation.

3.1.24.2.2. Rigging. Contractor personnel shall arrange for rigging services to off load the machine and contractor personnel shall be on site at Watervliet when the machine arrives and is off loaded to supervise the placement of the machine on the installation site by the rigging service. Outside rigging services should be advised that only certified grade 8 chains are permitted to be used at the Arsenal and that all rigging slings must be tagged and certified for the weights being lifted. Only propane powered forklifts are permitted and forklifts must also be equipped with a roll cage. Operators of forklifts shall have and be able to produce valid forklift licenses. The contractor shall ensure they bring all equipment/material necessary for the rigging of the machine. If necessary, the Watervliet Arsenal can provide the contractor with information for local rigging companies.

3.1.24.2.3. Installation. Once the machine is positioned and rough leveled by the contractor the contractor, through his own service personnel, shall be fully responsible for the startup and testing of the machine, conduct any acceptance tests specified in sections 3 and 4 and perform the required onsite training. The contractor and the service personnel shall remain until the machine activation and testing have been successfully completed. Under no circumstances should the contractor plan on gratuitous Arsenal assistance for diagnosis, troubleshooting or repair of the equipment during activation and testing. Should such activity prove necessary, it shall be the contractor's responsibility to provide the appropriate labor and materials. If the contractor chooses to request Arsenal assistance in lieu of providing their own resources, the request will be reviewed by the Technical POC who shall reserve the right to impose a charge for the assistance. Approvals, even on a charge basis, should not be taken for granted since there is no guarantee that appropriate Arsenal personnel will be readily available. In such cases, the Arsenal will not be held responsible for delays in acceptance of the equipment resulting from nonavailability of Arsenal personnel or Arsenal furnished equipment.

NOTE: Under normal circumstances the contractor will be allowed to work as long as is desired during normal work days. Contractor work outside Watervliet’s normal work days cannot be guaranteed. Watervliet is on a condensed work schedule. Normal work hours/days for this schedule are four 9-hour workdays (Friday off) one week and four 9-hour days, one 8-hour day (Friday) the following week. Contractor work on the Friday off and weekends cannot be guaranteed. Contractor’s classified as foreign nationals may further restrict work hours and days available.

If the contractor requests Watervliet Arsenal to ship misc. material via UPS, FedEx or by other similar carrier then the contractor shall provide their carrier account number for this purpose.

3.2. Machine Specific Requirements.

3.2.1. Machine Tool Description. The equipment covered by this specification shall be a Horizontal Type Ion Nitriding Furnace. The vessel is of cold wall construction and is configured to process batch loaded work pieces, positioned on a fixture, which is lowered onto an electrically isolated hearth. The batch load will be loaded and removed by battery operated “Walk-Behind” style loader.

3.2.2. Required Characteristics.

3.2.2.1. Performance Characteristics.

3.2.3. Required Features, Options and/or Accessories. The machine shall be fully designed, configured, and installed with the following features, options, and accessories in addition to the base machine design:

3.2.3.1. Vessel. The furnace casing shall be a welded steel structure consisting of a horizontal, cylindrical, and water jacketed, welded steel structure. The furnace shall have steel flanges and water-cooled dished heads. The work chamber shall be accessible through a water jacketed autoclave loading door with dual wall dished heads.

The vessel shall contain an atmosphere inlet, electrical and thermocouple lead-ins, vacuum outlet connection, resistance heat element lead-ins, and cooling water inlets and outlets. The vessel will leak tested during construction to insure a 10 micron/hour rate or less.

3.2.3.2. Sight Ports. Three (3) sight glasses of at least 4.5 inches in diameter shall be provided at suitable locations in the door and sidewalls of the vessel to allow the operator to observe the Ion Nitriding process.

3.2.3.3. Radiation Shields. Mounted on the interior wall of the vessel shall be two (2) stainless steel inner liners of at least 16 gauge thickness, acting as a radiation shield. The liner shall be easily removable for maintenance and cleaning.

3.2.3.4. Resistance Heating System. The unit shall be provided with a resistance heating system to preheat a workload to approximately 950°F. The Ion Power Supply in combination with the resistance heating shall provide heat to the work for the Ion Nitriding process. Graphite rod heating elements shall be hung in a circumferential pattern around the effective workload area. They shall be supported from power feedthroughs through the casing wall.

The resistance heating system shall be sized for 180 kW capacity and controlled by a variable reactance transformer.

3.2.3.5. Electrically Isolated Hearth. The electrically isolated hearth shall be suitably designed to accept loading a fixture with 4,000-pound gross load.

3.2.3.6. Vacuum Pumping System. The system shall be supplied with liquid ring mechanical vacuum pump, and a blower or booster to create a dual stage pump. The blower shall be driven by a 3 hp, 1800 RPM motor with a rated displacement of 335 CFM. The mechanical pump is driven by a 7.5 hp, 1800 RPM motor and has a displacement of 150 CFM. This mechanical booster vacuum pumping system shall be complete with piping, wiring, motors, starters, and controls in a NEMA 12 enclosure. The system shall include all valves and pressure controls.

3.2.3.7. Vacuum Control. A vacuum valve controller shall be provided that will work in combination with the Ion Power Supply to provide control to the furnace vacuum or partial vacuum levels during processing. The actual vacuum levels in the vessel will be measured by a capacitance manometer. Equipment shall have calibrated recording instruments for sensing, measuring, and recording pressure during the entire cycle.

3.2.3.8. Atmosphere Recirculating/Cooling System. A 20 hp, 1800 RPM fan/motor unit shall be mounted in the cover of the vessel for recirculating the atmosphere gas during the cooling cycle. A fabricated alloy fan wheel recirculates the inert gas atmosphere through the work during the cooling cycle. This recirculated gas shall be cooled as it is forced between the water-cooled vessel wall and the radiation shields. Typical operating pressure shall be 2” Hg vacuum.

3.2.3.9. Gas Control System. During the Ion Nitriding process, gas composition and flow rate shall be automatically controlled according to a predetermined selection dependent upon the specifications required of the nitrided surface layer and case. The gas for Ion Nitriding blending shall be accomplished utilizing the Ion Power Supply in conjunction with an automatic gas-mixing system. Each of the process gas flow rates shall be controlled automatically by using Electronic Mass Flow Controllers. Equipment for mixing gases shall be calibrated and capable of providing a measured ratio of components to within +/- 3% by volume of the selected value at a minimum.

3.2.3.10. Power Supply. Power supply shall deliver up to 60 kW at a peak voltage of 1000 VDC. The power supply unit shall operate in pure DC mode or in programmable pulse power mode. In pulse power mode, the power supply shall operate at frequencies up 15 kHz at various duty cycles.

The power supplies shall communicate digitally to an Allen Bradley PLC through Profi-Bus communications. Power supply pulse width shall be programmable as part of the ion nitriding recipe.

The temperature of work pieces shall be regulated by controlling the power supply output kilowatt level with a PID loop in the Allen Bradley PLC. The power supply shall be enclosed in a freestanding ventilated “rack mount” style enclosure. The power supply shall be water cooled. A refrigerant based chiller shall be included with the water system.

3.2.3.11. Process Controller. A process control shall be provided for control of vacuum and temperature levels during operation. The process controller shall be supplied with power supply, analog and digital I/O modules, Ethernet switch, and Allen Bradley PanelView Plus color display operator interface terminal. The process control system shall provide control of the following:

a. Ramp-Soak Temperature Control.

b. Automatic Vessel Pressure Control.

c. Automatic Partial Pressure Control Set points related to load temperature.

d. Process and Safety Alarm Monitoring.

e. I/O Status.

f. 250 Recipe Storage for Process Cycle Control.

g. Gas Flow Control Set points to Mass Flow Controllers.

3.2.3.12. Control Cabinet and Instrumentation. A double door, pre-wired, control cabinet with front access shall be provided. Mounted on the cabinet door shall be the Allen Bradley HMI, Vacuum/Partial Pressure Controller, high limit instrument, start-stop push button and emergency "Power-Off" push button.

3.2.3.13. Thermal Digital Recorder. A paperless temperature recorder will interface with the PLC to record process variables (thermocouple temperatures, wall thermocouple temperature, pressure, voltage and current). The recorder is also capable of recording cycle set points.

3.2.3.14. Closed Loop Water Glycol Cooling System. A cooling system for the furnace jacket shall be provided that requires no make-up water, and no continuous chemical treatment. Cooling fans shall be 1.5 hp at a minimum. Cooling Duty of the system shall be 90 GPM of 40% Glycol cooled from 113°F to 99°F with 92°F ambient air 573,000 Btu/hr.

3.2.3.15. Ion Power Supply Chiller. Chiller shall be refrigeration based and provide cold water at all times to the power supply. It shall be a closed loop circuit and tank. Chiller rating shall be a minimum 20,000 Btuh capacity when supplying 65°F water @ 95°F ambient. Operating range of outlet water temperature is 50°F to 80°F

3.2.3.16. Process Development. For each Part Number provided, the following shall be established and documented: the minimum and maximum number of parts allowed per load, the loading layout (a sketch, diagram, or photograph of part locations and thermocouple locations), masking/fixturing, processing parameters, specimen type and locations, and testing practice.

3.2.4. Interconnecting Wiring. All wiring shall comply with accepted Joint Industry Code (JIC), National Machine Tool Builders Association (NMTBA) and the National Fire Protection Association (NFPA) standards.

3.2.5. Control/Operating System Software and Documentation. One copy of the touchscreen software, ladder logic, probe system software, Licensed operating system, Fanuc or other control system software, interface software, and all pertinent documentation are to be provided prior to final acceptance as applicable. If the control provided is equipped with a flash card reader then a flash card loaded with the final version of the system software shall be provided with the final documentation. Also to be provided is a control system bill of materials for the control and drive systems detailing all control system standard features/options (with mfg. option numbers) and axes/spindle drive motors and drive package identifying information. Ladder logic documentation provided shall include a listing of logic error/alarm messages and a cross reference list of the full descriptive relay contact and coil names to the abbreviated names in the logic.

3.3. Requirements for Demonstration of Conformance.

3.3.1. Certification, Drawing and Test Required. The contractor shall demonstrate the machine’s conformance to all requirements elsewhere specified in section 3 of this specification. The contractor shall also, as a minimum, provide the following certification and perform the following specific tests:

3.3.1.1. Certification of Completeness. The contractor shall provide written certification that the machine is complete, including all specified systems, accessories, markings, safety devices, geometric and accuracy requirements. The certifications shall be provided to the Technical POC 14 days prior to the scheduled preliminary testing.

3.3.1.2. Test Workpieces. For both the preliminary and final acceptance tests the contractor will be required to demonstrate control functions, capabilities and cycling by means of ion nitriding test parts.

3.3.1.3. Final System Test. A demonstration of all machine functions while ion nitriding a vessel load of at least four specimens shall be performed to specified requirements. The lot shall be all parts of the same alloy and configuration, heat treated to the same requirements and nitride in the same vessel and at the same time. Actual parts are the preferred test specimen and shall be used when practical. Representative specimens may be used in lieu of actual parts and shall be fabricated from the same alloy, shall be similar in configuration, surface condition and geometry, and shall have the same processing history as the parts to be represented. The workpieces shall be subjected to the following control tests:

a. Total Case Depth

b. Effective Case Depth

c. Surface Hardness

d. Compound Layer Depth

e. Uniformity of Nitride Case

f. Examination of Microstructure

4. Quality Assurance Provisions.

4.1 Responsibility for Inspection. The contractor shall be responsible for performing all certifications and tests required in section 3.4 and shall provide materials, supplies and equipment as are specified.

4.2 Preliminary Acceptance Inspection. Preliminary acceptance inspection shall occur at the contractor's facility prior to machine shipment to WVA and shall consist of the certifications and tests specified in paragraph 3.3. When these tests are completed successfully, the contractor shall provide no less than 14 calendar days’ notice to the Arsenal Contracting Officer that the machine is ready for the preliminary acceptance inspection. This notification shall also include for review the test results of all preliminary tests performed. If test results are acceptable, the Arsenal representatives will schedule an inspection and the contractor shall await the arrival of the Arsenal representatives before starting the official inspection.

4.3 Arsenal Participation in Preliminary and Final Acceptance Inspection.

4.3.1 Examination for…