Attachment_2_-_Minimum_Specifications_Amended.pdf

Specification of Work

160kV and 450kV X-ray Systems

Revision: 2 June 2016

C.1 SCOPE

This specification sets forth the overall scope of work which will be performed to support a contract for the procurement of one each 450kV and 160kV x-ray systems. The new systems will be used to support the radiography test mission at the US Army Yuma Proving Ground (YPG). Compatibility of the new equipment and existing equipment is essential.

C.2 APPLICABLE DOCUMENTS

ASTM E1742 Standard Practice for Radiographic Examination

ANSI/NFPA 79 Electrical Standard for Industrial Machinery

DA PAM 385-64 Ammunitions and Explosives Safety Standards (Section 2, 6-10, 11&12 and Section 3, 6-13)

EN12543 Characteristics of Focal Spots in Industrial X-ray Systems for Use in Non- Destructive Testing

EN 50081-2 Electromagnetic compatibility. Generic emission standard. Industrial environment

EN 50082-2 Electromagnetic compatibility - Generic immunity standard

EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use

C.3 TEST FACILITY

Conditions to which the equipment will be exposed to include, but are not limited to:

Indoor, Industrial Environment.

Dust, temperatures, and humidity associated with an indoor industrial environment at YPG.

X-ray equipment will be exposed using the following X-ray energies:

6MeV and 3.5MeV (Linatron M6A Linear Accelerator (LINAC) 0-450kV (Tube Sources)

The YPG x-ray facility consists of a below-grade exposure bay and ground-level rooms and offices. All x-ray inspections occur within the bay. The upstairs areas are where personnel operate equipment from, and where data is collected, processed, and reviewed.

The exposure bay is approximately 56 feet long and 21 feet wide. The support structure for a Robotic Ammunition Handling System (RAHS) gantry robot is emplaced in the bay. There are two interlocked points of entry.

Figure 1: X‐ray Bay

Figure 2: X‐ray Bay Floor Plan

The primary source for current operations is a single LINAC X-ray Head and RF Unit is mounted on a lift table for beam height adjustment and has a fixed orientation. The LINAC is equipped with an external collimator.

Figure 3: LINAC and lift table

Dimensions are approximate, each Square ~1ft2

- Emergency Stop Location

Personnel Door Bay Door

Manipulator Pit

450kV and 160kV tube sources are both mounted to a modified BigJoe 1518-A6 pallet stacker with hydraulic lift for beam height adjustment. When these tubes are used, the assembly is wheeled in front of the LINAC X-ray Head facing the imaging area. The current 450kV source is a Varian NDI 450Be circa 2012 mated to a bipolar Phillips 450kV system (HV Generators, cooler, controller) circa 2000. The HV Generators have failed, and the cooling system is failing. The 160kV source is a unipolar Phillips system circa 1996. The tube has failed.

Figure 4: BigJoe X‐ray Tube Stand

Also present are two Lorad air-cooled field units (160- and 300-kV). Although not typically utilized for operations at the X-ray facility, they are used for remote operations, or when the facility’s other systems are down.

Operations using the system are typically be performed as follows:

YTC personnel receive test articles as determined by mission need, and select the appropriate x-ray source with which to perform the inspection. The test the article(s) are placed in front of the inspection area either on a table or manipulator (DR, CR, Film or Real-Time). YTC personnel exit the interlocked exposure area prior to energizing the x-ray source. The X-ray source is energized, and the image/video capture process initiated. Following data capture, personnel key the x-ray system to “safe” mode, and enter the bay to reset test articles in the inspection area. Personnel review the image(s) or video, post process, store locally, or send raw or post-processed DICONDE compliant images to the existing workstations for additional review, post processing, and archiving.

General inspection requirements require sufficient sensitivity to detect inclusions, cracks and voids in explosives; damaged, loose, or missing components; unsafe fuse and safety conditions; and other anomalies that may arise during manufacturing, shipping, handling, storage, and testing.

Items inspected include, but are not limited to:

All types of 155mm and 105mm artillery projectiles All types of 60mm, 81mm, 120mm mortars All types of artillery and mortar fuzes

2.75-inch rockets with or without warheads 120mm Tank Ammunition Foreign artillery, mortars, rockets, and other munitions Other munitions under test of varying size and configuration Non-munition items including castings, weapon and automotive system components

C.4 Equipment Salient Characteristics

NOTE

The proposing company shall enter compliance (C – fully meets the requirement), non-compliance (NC – does not meet all or part of the requirement) or exception (E – the requirement is partially met or the requirement is met in a different way) for each requirement and bullet. A statement is requested for any non-compliance or exception.

Specify make & model of each component offered.

C.4.1 General:

The contractor shall provide all necessary equipment, hardware, cabling, fittings, connectors, lubricants, coolants, solvents, hoses, and any other items necessary for the installation of the equipment.

The following requirements shall be met or exceeded for all equipment and components provided by the vendor:

o All components shall be new and Original Equipment Manufacturer (OEM). No demonstration or used components are acceptable.

o Equipment shall be standard equipment which is already in production. Equipment purchased via the contract shall be shipped within 90 days of receipt of Delivery Order.

o Manufacturing standards shall be ISO 9001:2008 compliant.

o Components shall meet or exceed ANSI/NFPA 70, National Electric Code o Components meet specifications in C.2.

o All equipment shall maintain full function with no loss of fidelity when exposed to the environmental conditions described in C.3. No damage or degradation to the system shall occur, and all equipment shall have a 100% duty cycle when exposed to those conditions.

o As necessary, equipment shall be adequately shielded to minimize the damaging effects of exposure x-ray radiation at the energy levels described in C.3 during radiographic operations.

o The systems shall be used for acquisition of both 2-D video-radiographic data, DR, CR, and film radiographic still images. The system may be used for Thee-dimensional (3-D) Cone Beam Computed Tomography (CBCT).

o New equipment shall be installed in the location of old equipment it is replacing o Onsite training for a minimum of 1 days for a minimum of four personnel.

At a minimum, the training shall cover theory of operation, equipment operation, software operation, and system maintenance.

The equipment vendor shall provide necessary training documentation.

YPG shall retain control of the existing X-ray systems and all parts native to the X-ray systems

C.4.2 450kV X-ray System

A complete 450kV x-ray system minus the x-ray tube

High Voltage Generators – Salient Characteristics o Bipolar System 4500W 40 - 450kV ± 1% Demand Minimum ± 0.05kV reproducibility Minimum 40kV per second rise time No more than 10.0V/mA HV Ripple with a 30 feet cable Minimum 25kHz Drive Frequency 0 – 20 mA ± 0.05% Demand Minimum ± 0.002mA reproducibility 220V, 60Hz, 27A input o Built-in voltage, power and tube current safety limits o Automatic variable converter frequency to maximize efficiency o o Designed for field service and repair of high voltage tank o RS232 Interface o Modular design and backward compatible upgrades o o Same brand as the 160kV system defined in this document

Controller – Salient Characteristics o Mounts in 19” equipment rack o RS232 Interface o Capable of PC control o Microprocessor control via serial control with data logging for trouble shooting o User definable automatic warm up settings o Monitors the x-ray tube mA and kV to ensure precise and stable output o Monitors interlock status and generator status for system and personnel safety o Configurable automatic restart following tube arc events to minimize system downtime o Open architecture software to allow for system integration o Keyed safety switch to prevent system operation without the included system key o Warning lamp or equivalent visual alarm which alerts the operator when the tube is energized o Output connection for an external flashing warning lamp o The system shall have an input connection for safety interlocks o The system shall have an emergency stop button o Same brand as the 160kV system defined in this document o The new tube shall have dual focal spots with one focal spot not exceeding 2.5 mm diameter and the other not exceeding 5.5 mm diameter o At minimum, tube current shall be adjustable up to 10 mA in 0.1 mA increments o At minimum, tube voltage shall be adjustable up to 450 kV in 1 kV increments o The tube shall provide a flat mounting surface at the window for mounting a collimator

4.5kW Oil Cooler – Salient Characteristics o Closed circuit o Adjustable bypass valve o Adjustable safety flow switch o Over temperature safety switch o Cooling Medium – transformer oil o Minimum 4.5kW cooling capacity at 39°F temperature delta o Minimum flow rate 6 gallons per minute at 50psi o Maximum 65dB at 3 feet o The oil cooler shall be tuned for proper operation with the x-ray tube being connected to prevent damage to the x-ray tube o New hoses with quick release fittings at each end shall be installed.

Cabling – Salient Characteristics o Electrical interface Box Shared with 160kV System C.4.3 Accommodates existing safety and interlock circuits o Cabling to interconnect the entire system for stand-alone capability.

o Connections to existing building power o Connections to existing e-stops o New High Tension Cables connecting the tube head to the High Voltage Generators shall be installed (minimum 32ft each) o New quick lock connectors for the High Tension cables shall be installed o System shall be controlled from the upstairs work area

Compatible with existing 450kV Varian NDI-451 Be dual focus X-ray tube

X-ray system shall be turn-key and operational upon delivery when power, controller, and tube connections are made by the offeror.

C.4.3 160kV X-ray System

A complete 160kV x-ray system including dual focus x-ray tube

High Voltage Generator – Salient Characteristics o Unipolar System 3200W 10-160kV ± 1% Demand Minimum ± 0.05kV reproducibility Minimum 20kV per second rise time No more than 5.0V/mA H.V. Ripple with a 30 feet cable Minimum 25kHz Drive Frequency 0 – 30 mA ± 0.05% Demand Minimum ± 0.002mA reproducibility 220V, 60Hz, 27A input o Built-in voltage, power and tube current safety limits o Automatic variable converter frequency to maximize efficiency o o Designed for field service and repair of high voltage tank o RS232 Interface o Modular design and backward compatible upgrades o o Same brand as the 450kV system controller defined in this document

Controller – Salient Characteristics o Mounts in 19” equipment rack o RS232 Interface o Capable of PC control o Microprocessor control via serial control with data logging for trouble shooting o User definable automatic warm up settings o Monitors the x-ray tube mA and kV to ensure precise and stable output o Monitors interlock status and generator status for system and personnel safety o Configurable automatic restart following tube arc events to minimize system downtime o Open architecture software to allow for system integration o Keyed safety switch to prevent system operation without the included system key o Warning lamp or equivalent visual alarm which alerts the operator when the tube is energized o Output connection for an external flashing warning lamp o The system shall have an input connection for safety interlocks o The system shall have an emergency stop button o Same brand as the 450kV system controller defined in this document

3.2kW Water Cooler – Salient Characteristics o Closed circuit o Adjustable bypass valve o Adjustable safety flow switch o Over temperature safety switch o Cooling Medium – Water o Up to 4kW cooling capacity at 18°F temperature difference o Minimum flow rate 1.5 gallons per minute at 87psi o Maximum 65dB at 3 feet o The water cooler shall be tuned for proper operation with the x-ray tube being connected to prevent damage to the x-ray tube.

o New hoses with quick release fittings at each end shall be installed.

160kV Dual Focus X-ray Tube – Salient Characteristics o 0.8mm integrated Be filter o To be mounted on existing BigJo lift o Small Focal Spot

1.0 per EN12543 Continuous rating: 640W Up to 160kV o Large Focal Spot

5.5 per EN12543 Continuous rating: 3000W Up to 160kV o Radiation coverage angle shall be between 35- and 45-degrees o The tube shall provide a flat mounting surface at the window for mounting a collimator

Cabling – Salient Characteristics o Electrical interface Box

Shared with 450kV System C.4.2 Accommodates existing safety and interlock circuits o Cabling to interconnect the entire system for stand-alone capability.

o Connections to existing building power o Connections to existing e-stops o A minimum 32 ft long High Tension cable connecting the tube head to the High Voltage

Generator shall be installed o “Quick Lock” connectors for the High Tension Cables shall be installed o System shall be controlled from the upstairs work area

X-ray system shall be turn-key and operational upon delivery when power, controller, and tube connections are made by the offeror.

C.4.4 Option 1 – 450kV Dual Focus X-ray Tube

A dual focus x-ray tube to replace the existing Varian Tube – fully compatible with system as delivered per this document.

450kV Dual Focus X-ray Tube – Salient Characteristics o Bipolar o 0.8mm integrated Be filter o To be mounted on existing BigJo lift.

o Small Focal Spot

1.0 per EN12543 Continuous rating: 640W Up to 160kV o Large Focal Spot

5.5 per EN12543 Continuous rating: 3000W Up to 160kV o Radiation coverage angle shall be between 35- and 45-degrees o The tube shall provide a flat mounting surface at the window for mounting a collimator

C.4.5 Documentation

The Contractor shall provide all manuals and literature pertaining to the equipment being installed. This shall include, but is not limited to:

Specification sheets and manuals for the X-ray systems and tubes:

o Manufacturer’s test certificate o Records showing the tube has been properly seasoned while on-the-shelf o Published exposure chart for the X-ray tube model o Exposure chart for the tube (if available) o Others as applicable

Parts list for all equipment, hardware, cabling, fittings, connectors, coolants, and lubricants used during the installation o Part list shall include part number, serial number (when applicable), and manufacturer of the part

Detailed notes and diagrams regarding modifications and changes made to the existing safety interlock system, RTRIS, and tube head positioner to accommodate the new X-ray tube

Manuals detailing preventative maintenance, operation, and troubleshooting with respect to the X-ray tube and all components installed or modified by the contractor

C.5 Customer Support:

Delivery and support shall include, but is not limited to:

Delivery of completed design drawings within 45 days after acceptance of contract.

Delivery and on site system installation and calibration: the system shall be installed and calibrated within 180 days after acceptance of final system design. Scheduling the installation will require coordination with YPG to minimize impact to the mission – installation may have to occur during non-working hours to accommodate test mission.

The equipment vendor shall provide a minimum of two complete hardcopies and one electronic copy of electrical schematics, mechanical drawings, and operation and system maintenance manuals, including a complete parts list with make and model of all components.

C.6 Warranty The vendor shall provide a warranty for the equipment which is provided to YPG. The warranty length shall be a minimum of one year from date of acceptance, and guarantee equipment work properly and be free of defects caused before delivery of the system, or through normal use. The vendor warranty shall cover all parts and labor for the system to include free software updates and patch releases, and e-mail and telephone technical support