A.1-2_Revised_Salient_Characteristics_and_Technical_Requirement.doc

DSCR-JHTB-96-19-1009

4 MARCH 1996

A.1 Salient Characteristics and Technical Requirement

HEAT TREAT FURNACE

C-1 SCOPE. This specification sets forth the minimum requirements for the procurement of one (1) Heat treat Furnace, to include all components and equipment specified herein.

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

AMS 2750E – Pyrometry

AMS 2770N – Heat Treatment of Wrought Aluminum Alloy Parts (Application for copies should be addressed to SAE International, 755 W. Big Beaver, Suite 1600, Troy MI 48084)

C-2.3 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption is obtained.

C-3 REQUIREMENTS

C-3.1.2 Safety and Health Requirements. Covers, guards, or other safety devices shall be provided for all parts of the furnace that present safety hazards. 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. An energy isolation device shall be installed on the machine designed to accept a lockout device. All furnace parts, components, mechanisms, and assemblies furnished on with the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA Safety and Health Standards (29CFR 1910).

C-3.1.2.1 Audible Noise Levels. Audible noise emitted by the equipment shall not exceed 84dba at the operator's work position nor at any other point at a distance of three (3) feet from the equipment.

C-3.1.5 Maintainability. The equipment shall be designed and constructed to permit maintenance personnel to easily and effectively service the equipment using a minimal number of tools. Consistent with required maintenance and design of the equipment, the contractor shall provide any special tools required to service the unit. Additionally, the equipment shall be equipped with access covers to facilitate inspection, cleaning and repair or replacement of parts.

C-3.1.7 Marking on Instruments, Control Panels, Charts, and Plates. All words on instruments, control panels, charts, and plates shall be in the English language. Characters shall be permanently marked.

C-3.2 Components. The system shall be designed to meet or exceed the requirements for the initial and periodic inspections, calibration and certification standards for temperature uniformity, loaded heating recovery, and temperature control specification requirements as stated in USAF T.O. 1-1A-9, Boeing Process Specifications BAC 5602 and 5621K, McDonnell Douglas Corporation - Douglas Process Standard DPS 1.700, Airbus 80-T-36-1010, and the Society of Automotive Engineers, Inc. - Aerospace Material Specification AMS 2750E and AMS 2770N.

The system shall consist of a dual chamber furnace in a stacked (one on top of the other) configuration.

The system shall include a stainless steel rollaway water quench tank.

The system shall include a furnace temperature controller and temperature recorder sufficient to meet the annotated specifications while operating both chambers independently.

The system shall include a quench delay timing system.

C-3.2.1 Heat Treating/Aging Furnace. The Furnace and its associated systems shall be capable of achieving NADCAP certification for heat treating Aluminum for aerospace applications.

Dimensional and Temperature Requirements:

Overall Furnace with operator station and all peripheral equipment shall not exceed: 108"W x 170"H x 170"L

Chamber Dimensions shall be: greater than or equal to 12"W x 12"H x 24” D 1st Chamber Max temperature: no less than 2000F

2nd Chamber Max temperature: no less than 1200F Steel Construction and Refractory: The outside casing of the furnace should be designed for rugged industrial applications.

Re-circulation Air Fans and Baffling System: Each chamber shall incorporate a high volume re-circulating air fan.

Each chamber shall include a port adjacent to each of its control and recording thermocouples for the passage of the SAT (system accuracy test) thermocouples. A TUS frame will be provided with the unit that is compatible with high temperatures. A manual, back-up TUS capability shall be included to be used in the event a recorder is not available for the TUS.

C-3.2.3 Automated Temperature Recorder. Sufficient recording channels are required for a recorder or data acquisition system to comply with AMS2750E for both chambers simultaneously including the oven control or display temperature, the TUS High / TUS Low positions and the additional quench tank thermocouple. Compliance to AMS2750E is required for NADCAP certification. The recorder and provided software must include the AMS2750E features to track SAT, TUS, and calibration times to alert the operator to potential deviations to AMS2750E compliance. The recorder also provides an overview of T/C usage for all survey T/C’s providing a color coded for early warning screen (5 day expiration and past due). All instrumentation needs to comply with Type “C” per AMS2750E. Batch software must be included to order to provide a secure record of any parts heat treated. Batch records must be readily retrievable and include all temperature and time stamps to prove proper heat treatment – including quench time delay. Software must be included for network monitoring of the heat treatment process, including remote viewing and records printing. The provided software must enable the operators to easily print out a record of the heat treating profile and include all pertinent information to prove a proper cycle.

C-3.2.4 Quench Tank. The quench tank shall be a stainless steel tank The tank shall be capable of being fitted with a high capacity submersible pump of the manufacturer’s design, or as provided by the manufacturer as a normal optional item. This shall be an offered option for agitation and maintaining uniform temperature. Operation of the pump must have both a manual and automatic mode. An additional thermocouple shall be installed and capable of communication with the temperature recorder for water temperature monitoring.

C-3.2.5 Quench Timing System. The system should will have the capability of measuring and recording to the Temperature Recorder the time elapsed between the chamber opening and the metal entering the quench tank.

C-3.2.6 Thermocouples. Each of the two chambers shall have five thermocouples for use in production; the primary temperature controller's, the high limit controller’s, and the recorder’s – chamber temperature and high/low TUS. For compliance to AMS-2750E, provisions shall be made to mount the two additional (High/low TUS) thermocouples to monitor the highest and lowest temperature locations of the most recent TUS. Each chamber shall include provisions to mount the SAT thermocouples. A TUS frame will be provided with the unit that is compatible with high temperatures.

Along with the five production thermocouples, all necessary thermocouples, of the correct types, to perform the TUS and SAT shall be provided along with the necessary cabling and junctions. All thermocouples shall be provided with current N.I.S.T. certified calibrations.

C-3.3.2 Utilities Interconnection. The Furnace shall be capable of operating from Government supplied 460 volts, 60 hertz AC power available at the site.

Air Supply:

All air-operated equipment shall be capable of operating from an air supply of 120 psi.

The contractor shall install an electric power disconnect switch which shall be located about 4 feet above the floor near the equipment. If there are no stanchions near the equipment, the disconnect junction box may be mounted on the outside of the equipment in an easily accessible location. All machine mains for the system shall be routed through the electric disconnect switch.

C-4 QUALITY ASSURANCE TESTING

C-4.1 Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein. The contractor may use their, or any other, facility suitable for the performance of the inspection requirements specified herein. All testing shall be done on site after installation.

C-4.5.3 Operational Test. The furnace and its control and recording systems shall be operated in accordance with the manufacturer's standard operating test procedure for warm-up (if necessary) and operational checks. A System Accuracy Test (SAT) shall be performed according to AMS 2750E. Afterwards, a Temperature Uniformity Survey (TUS) shall be performed according to AMS 2750E. All parameters tested shall conform to those standards and shall be in compliance with the necessary standards such that the furnace could be classified as a Class 1 furnace according to the specifications.

C-4.5.5 Performance Test at Destination. The performance tests require three parts. Part 1 shall be the Heat treatment of a coupon of 2024 Aluminum sheet to W temper. Part 2 shall be the heat treatment of a coupon of 7075 Aluminum sheet to W temper. Part 3 will require the aging of the 7075 coupon to a T76 temper. These tempers will be verified via conductivity and hardness testing within 10 minutes of quenching for the initial W tempers and after aging for the T76 temper.

The Performance Test can be combined with the Program verification test at the contractor’s request.

C-4.5.6 Documentation. The contractor shall provide three (3) sets of the following documentation in the English language: Operators, programming, electrical maintenance, mechanical maintenance, parts lists, electrical schematics and ladder logic diagrams. One (1) set of subject documentation shall be furnished to the government 10 days after government approval of 100% design review and the balance of two (2) documentation sets shipped with the machining cell.

C-5 TRAINING

C-5.1 Operation/Programming. Within 10 days of acceptance at Kunsan AB, the contractor shall conduct a minimum of 36 hours of on-site training over five consecutive work days, during the hours of 0645 to 1530 for up to four (4) operators. The training shall include instruction and demonstration of both furnace operation and programming of the control unit, as well as use of unique features and/or accessories provided. Training shall highlight the features that lead to compliance with AMS 2750E and AMS 2770N. Training shall be scheduled so as to not interfere with any Federal Holidays.

INSTALLATION RESPONSIBILITIES

Government Contractor

(XX) ( ) a. Provide machine foundation in accordance with the manufacturer’s design requirements.

(XX)

b. Furnish labor and material handling equipment for off-loading and placing item on foundation.

(XX)

c. Provide and install anchor bolts and nuts.

(XX)

d. Set and rough level the machine on its foundation.

(XX)

e. Level and align machine.

(XX)

f. Connect machine to the provided utilities hook-up.

(XX)

g. Provide all necessary materials, tools, gages and instrumentation necessary to perform the required tests.

(XX)

h. Provide and charge all systems with fluids in accordance with manufacturer's instructions.

(XX)

i. Material and tooling required of the performance testing at Government facility.

GOVERNMENT RESPONSIBILITIES

(XX) Provide unobstructed utilities hook-up within 40 feet of machine.

(XX) Assign one maintenance mechanic (mechanical/hydraulic) and one

Maintenance mechanic (electrical/electronic) to provide information and limited additional materials for the contractor's representative during installation, verification, and initial start up of the machine.

(XX) No work shall be performed by customer personnel when the contractor's representative is not in the immediate work area during installation, and initial start up of the machine.

CONTRACTOR RESPONSIBILITIES

(XX) Upon verifying and certifying the machine is correctly installed, demonstrate the operation and performance of the equipment. Verification of installation shall be included within the warranty.