Specs.pdf

VACUUM FURNACE SYSTEM UPGRADE

Scope of Work Provide services to upgrade two (2) Government owned high-temperature vacuum furnaces from analog controls to a Programmable Logic Control (PLC) system. The two vacuum furnaces, designated as ABAR II and ABAR III, are in operation at the Structures Testing Laboratory located at NASA Langley Research Center, Building 1148, Rm 104, Hampton, VA. The operational characteristics, auxiliary equipment, and manufacturing identification information for these furnaces are listed in Table 1 and Table 2 below. Close-up views of the vacuum furnaces and auxiliary equipment are provided in the attached PowerPoint presentation.

Table 1. Specifications and auxiliary equipment for the ABAR vacuum furnaces.

ABAR II ABAR III

Temperature Rating: 3000 F / 1649 C. Temperature Rating: 3000 F / 1649 C.

Hot Zone: 24”W X 24”H X 48”L Hot Zone: 24”W X 18”H X 36”L Hot Zone Load Limit: 600 pounds Hot Zone Load Limit: 600 pounds Heating Element Material: Molybdenum Heating Element Material: Molybdenum Heat Shield Material: Molybdenum Heat Shield Material: Molybdenum Rough Pump: Stokes 212-H, 150 CFM Rough Pump: Stokes 212-H, 150 CFM Diffusion Pump: N.R.C # HS-20 Diffusion Pump: N.R.C # HS-20 Auto Controlled LN2 Cold Trap Auto Controlled LN2 Cold Trap TeleVac MX200 Vacuum Controller:

3 channels; two 4a 0-1000 torr convection gauges (1) foreline, (1) chamber 7B Pennington cold cathode gauge for high vacuum

TeleVac MX200 Vacuum Controller:

5 channels; (2) 4a 0-1000 torr convection gauges: (1) foreline, (1) chamber 7B Pennington cold cathode gauge

(1) MKS capacitance manometers (0-1 torr)

(1) MKS capacitance manometers (0-1000 torr)

Roughing Valve Roughing Valve Foreline Valve Foreline Valve High Vacuum Valve High Vacuum Valve Chamber roughing thermocouple gauge Chamber roughing thermocouple gauge Roughing/Foreline thermocouple gauge Roughing/Foreline thermocouple gauge Chamber Cold Cathode gauge Chamber Cold Cathode gauge LN2 supplied tank and plumbing, optional mobile Dewar connection

LN2 supplied tank and plumbing, optional mobile Dewar connection

Power Supply: 200KVA, 460VAC, 3-phase, 60Hz Power Supply: 160KVA, 460VAC, 3-phase, 60Hz Gas Blower: Spencer 1200 CFM Gas Blower: Spencer 1200 CFM Closed Loop Watering Cooled Heat Exchanger Closed Loop Watering Cooled Heat Exchanger Mini Trend QX: Vacuum/ Temperature Recorder Mini Trend QX: Vacuum/ Temperature Recorder Eurotherm 2404 Programmable controller Eurotherm 2404 Programmable controller Honeywell Programmable over-temp controller Honeywell Programmable over-temp controller Automatic Pump Down/Heat Cycles Automatic Pump Down/Heat Cycles

Table 2. Manufacturing identification information for the ABAR vacuum furnaces

Vacuum furnace: ABAR II ABAR III Manufacturer: ABAR Corp. ABAR Corp.

Bill of materials number: BM-388-1 BM-734 Manufacture date: 1973 1981 Government equipment control number:

418688 418696

Scope of this Solicitation:

Proposals are sought from vendors who specialize in vacuum furnace control and data acquisition systems to upgrade both vacuum furnaces from analog controls to a Programmable Logic Control (PLC) system. The PLC system shall integrate furnace controllers, overtemp controllers, and vacuum controllers through a single interface. System shall be able to perform data acquisition, store multiple programs, allow manual and automatic control, and be interlocked to the vacuum system for proper valve actuation with respect to normal vacuum furnace system operation. An operator interface terminal shall be provided in the control cabinet for a single point of operation. The proposal shall include removal of all old obsolescent, non-essential instrumentation, i.e., analog strip chart recorders and analog controllers. The scope of work shall include on-site training of the PLC controller and software system for the equipment operators.

Detailed Requirements:

Provide a state-of-the-art logic and process controller for both vacuum furnaces along with an Operator Interface Terminal (OIT) that serves as a data collection device capable of storing 200 days of data that can be exported as a CSV file to an USB Flash drive. The system shall integrate the existing temperature controllers, overtemp controllers, and vacuum controllers. Appropriate software configured for the systems shall be provided.

Control Requirements:

1. Vacuum Hold feature that puts the program into a Hold cycle until the desired vacuum level is achieved before initiating the heat cycle. Once heat is enabled the program will switch back to run.

2. Soak timer feature that enables the program to be put on hold until all thermocouples are within the desired temperature soak band.

3. Outgas hold feature to hold the program while outgassing occurs. If outgassing occurs, the program should be put on hold to enable the pumping system to reach the desired vacuum level before initiating the heat cycle.

4. Thermocouple (T/C) Correction Factors shall be incorporated to ensure accurate temperature readings.

5. Temperature Range Tuning shall be implemented (Tuning sets based on temperature ranges that change automatically from one temperature range to the next).

6. Vacuum Leak Rate Calculations should be incorporated into the program. (The scheme will check for all valves being closed and begin calculating the leak-up rate over a user specified test time. When the test time is complete, the leak-up rate is captured and stored until the next test.)

7. Automatic Hi-Limit Setting (Communications shall be setup between the PLC and the Hi Limit Controller) to write the set-point to the Limit controller per program basis.

8. Output Limiting algorithm shall be included that shall limit the max PID output below the temperature set-point to provide a soft start. Once above the set-point, the output should be gradually increased.

9. Logging system should be programmed to track run hours on the mechanical pump, booster pump, holding pump, diffusion oil life, hot zone, and cooling fan, to assist a maintenance program.

Government Furnished Equipment and Documentation

• Government furnished equipment:

o ABAR II and ABAR III vacuum furnaces. See Tables 1 and Table 2 and attached

PowerPoint presentation for further information.

• Government furnished supporting documentation for this equipment include:

o ABAR II: DWG NO. D-15060 Electrical Schematic, dated March 28, 1974 o ABAR III: DWG NO. D-27708 Rev. A: Electrical Schematic, dated January 5, Contractor Furnished Equipment PLC controller, data acquisition and control software and personal computer; doors panels, interface ports and ethernet switches for signal routing as required, vacuum / pressure transducers, interface to Contractor furnished PC for signal monitoring (2 each), and relays to provide interlock interface to existing Government equipment.

Contractor Furnished Labor Contractor shall furnish all labor for removal of existing instrumentation, wiring, switches and all other items not needed in this up-grade. Contractor shall furnish all labor necessary for installation, fabrication, wiring and checkout of the new PLC system including modification to existing ABAR equipment control cabinets.

Specifically, the contractor shall perform the following tasks for the upgrade:

1. Remove unused devices

2. Rewire controls other than 480VAC motor starters

3. Replace control wires from panel to first junction box

4. Re-label field wires from control panel to first junction box

5. Install pressure transducer with first junction box

6. Install pressure transducer with NW fittings

7. Replace motor starters and contactors for the following:

(1) 30HP, 50 KVA blower motor

(1) 30HP, 34 KVA blower motor

(2) 7.5 HP rough pump motors

(1) 0.5 HP holding pump motor All motor starters are 460 VAC three phase.

8. System test and mock survey for tuning & trims setup in accordance with AMS 2750F

9. Configure HC 900 controller, OIT and Specview software

Contractor Furnished System Checkout:

Contractor shall demonstrate in the presence of Government research engineer(s) and Government technician(s), functional checks and operational checkout after modifications are complete on each system.

Contractor Furnished Training:

The contractor shall provide training to NASA qualified operators and technicians for all operations of the PLC controller, control and data acquisition software, and interfaces.

Contractor Furnished Documentation

• Contractor shall furnish to Government research engineer all equipment manufacturers information data and specifications prior to award of contract and details of electrical interface to existing Government equipment with reference to existing Government drawings.

• Contractor shall furnish equipment manufactures operation, setup, installation, schematics and wiring manuals and drawings (2 copies each) for all equipment used.

• Contractor shall furnish calibration data sheets for all equipment used.

Government Acceptance Checkout Final Government acceptance checkout shall be operational checkout by Government technician(s) in the presence of contractor, using contractor generated procedure modified as needed by Government.

NASA points of contact The NASA technical point of contact for this solicitation is:

Eric Hoffman eric.k.hoffman@nasa.gov 757-864-3127

The NASA procurement point of contact for this solicitation is:

TBD

mailto:eric.k.hoffman@nasa.gov