SOLICITATION NOTICE
66 -- SOLAR ATMOSPHERE MANUFACTURING INC MODEL HFL-2624-EQ HORIZONTAL LOADING VACUUM HEAT TREATING ANDF BRAZING FURNACE
- Notice Date
- 9/5/2006
- Notice Type
- Solicitation Notice
- Contracting Office
- 3610 Collins Ferry Road (MS-I07) P.O. Box 880 Morgantown, WV
- ZIP Code
- 00000
- Solicitation Number
- DE-RQ26-06NT00914
- Response Due
- 9/20/2006
- Archive Date
- 3/20/2007
- Small Business Set-Aside
- N/A
- Description
- SUBJECT: SOLAR ATMOSPHERE MFG INC MODEL HFL-2624-EQ HORIZONTAL LOADING VACUUJM HEAT TREATING AND BRAZING FURNACE DESC: The U.S. Department of Energy??s National Energy Technology Laboratory (NETL), Pittsburgh, PA intends to award a purchase order on a sole-source basis to Solar Atmosphere Manufacturing Inc., Souderton, PA to purchase the following item (to be delivered to our site in Albany, OR). SOLAR MUNUFACTURING MODEL HFL-2624-EQ HORIZONTAL LOADING VACUUM HEAT TREATING AND BRAZING FURNACE WHICH INCLUDES AN ALLEN-BRADLEY PANEVIEW 1500 THAT PROVIDES OPERATINALA ND MAINTENANCE DIAGNOSTIC MESSAGES WITH THE FOLLOWING SPECIFICATIONS SMQ-06322: EQUIPMENT SPECIFICATION 1.0 GENERAL OPERATON & PERFORMANCE This furnace system should be designed for a high performance, low maintenance cost and energy efficient results. The vendor should have a proven track record providing such a component. 1.1 TEMPERATURE * Maximum operating temperature 2400?aF (1315?aC) * Temperature uniformity ?b 10?a (5?XC) between 800?aF (427?aC) to 2400?aF (1315?a C) * Maximum temperature for up to two (2) hours of clean out cycles is 2500?aF (1371?aC) * Uniformity meeting SAE Aerospace Materials Specification AMS-2750 1.2 VACUUM PERFORMANCE The following specifications are based on a clean, dry, empty and conditioned furnace. * Ultimate vacuum should be in the 10-6 Torr range. * Operating vacuum should be in the 10-5 Torr range * Evacuation time to high vacuum cross over should be typically less than 10 minutes * Evacuation time to 1 x 10-4 Torr, should be less than 15 minutes * The leak-up rate will be less then 5 microns per hour. It is understood that the actual evacuation time during process cycles may be longer due to outgassing from the process load. 1.3 HEATING PERFORMANCE A maximum heating rate of approximately 50?aF/min is required. 2.0 HOT ZONE DESIGN 2.1 The minimum work zone size is to be 18" (457 mm) wide x 14"(357 mm) high x 24?? (610 mm) deep. 2.2 The hot zone insulation should be made of high purity graphite felt blanket or similar material. All insulation material should be completely assembled in a heavy-duty .090?? thick #304 stainless steel structure. 2.3 Graphite heating elements mounted cylindrically in the hot zone are desired. Additionally, they should be divided into multiple trim zones and be divided into segments for ease of replacement. The heating elements supports should be designed to shield the ceramic insulators from the build up of metal plating that can cause arcing and shorts; such designs are covered by Patent Nos. 6,111908; 6,023,487; and 6,021,155. The heating elements are connected to water-cooled power terminal assemblies which are gas and vacuum tight. 2.4 The high velocity gas nozzles should surround the work load and for maximum cooling capability and uniform quench. 2.5 The hearth assembly shall be a pin and rail design and be completely removable. The hearth assembly will consist of molybdenum work support pins and heavy duty graphite work support rails with molybdenum rod inserts. * The hearth will be able to support a gross weight of 500 pounds (227 kilograms) at 2400?XF (1315?XC). 3.0 CHAMBER DESIGN FEATURES The chamber design should be round, double walled, water cooled, carbon steel (A-36) design and generally built to ASME codes and fully tested with a helium mass spectrometer. Flanges are machined from low carbon steel. Chamber penetrations such as the power terminals, vacuum pumping ports and gas quench system should be "O"-ring sealed with standard off-the-shelf Buna-N or Silicone based "O"-rings suitable for application in a vacuum system. The water jacket should be sufficiently large for the application and include large oversized water inlet and exit ports conveniently located allow for periodic flushing of the water jacket to reduce sediment build up if required. Chamber interior should be painted with a low out gassing, high temperature, low emissivity paint. The exterior should be painted. Ports should be provided for vacuum, gas recirculation system, gas backfill system, control and over-temperature thermocouples, work thermocouple assembly and power terminals. 3.1 CHAMBER DOOR DESIGN The chamber??s door shall be "O"-ring sealed, flanged, hinged and balanced to allow for a full swing for full unobstructed loading/unloading of work loads and fixtures. 4.0 VACUUM PUMPING SYSTEM DESIGN The pumping system shall consist of a diffusion pump backed by a mechanical pump and vacuum booster. All vacuum valves shall be interlocked for automatic and fail safe operation throughout the cycle. Should a power failure occur all valves shall automatically close to protect the load and furnace system. All vacuum pumps shall be provided with the proper fluids. 5.0 GAS SYSTEM DESIGN To provide the cooling rate, an external, two bar (15 PSIG) gas quenching system for high velocity gas flow is required. A low flow resistance, straight through all-copper water cooled fin and tube design heat exchanger is required in the blower can. The radial blower assembly should include a computer balanced radial pressure wheel that will be optimally sized for argon gas quenching. The gas quench motor should include a class ??H?? insulation and a thermal switch. A step-down transformer to prevent arcing and motor failure should be provided. The quench gas will be forced through the hot zone??s high velocity gas nozzles and designed for maximum performance at 2 bar (15 psig) using argon gas. One (1) 125 PSI, 34 cubic foot gas backfill reservoir with pressure gauge should be included. All pipes, flanges and seals should be included. 5.1 GAS BACKFILL ASSEMBLY The backfill system will include a connection for argon gas. The backfill pressure will be controlled automatically to the pressure level setpoint as an event in the cycle or program. At the end of cycle the chamber is vented to atmosphere. An ASCO solenoid valve is provided for backfill. 5.1 PARTIAL PRESSURE SYSTEM The two (2) gas partial pressure system operates at pressures based on the maximum capability of the mechanical pump and blower system. The partial pressure is programmed in the cycle. A solenoid valve controls the pressure. Flowmeters for both nitrogen and argon are provided for gas flow control. A VRC absolute pressure gauge shall be provided for partial pressure vacuum setting. 5.1 COOLING RATE The cooling rate is based on the ability of the process material to give up heat as well as the density and configuration of the load. The cooling system is designed to provide the highest volume of gas flow, at the highest velocity to the work load in the industry. 6.0 WATER SYSTEM DESIGN The furnace is equipped with an inlet and outlet manifolds for connection to a customer supplied water system. The plan is to plumb this water system into one of our cooling tower systems. All feed and drain hoses will be neoprene rubber with brass fittings. The water system will be designed with pressure regulators and valves and flow indicators installed on critical lines of operation. 6.0 POWER SUPPLY An angle fired SCR transformer is required. The power supply should be divided into 2 trimmable heating zones with two (2) transformers at 35 KVA each for a total of 70 KVA of hot zone power. The power supply should be mounted in a nema enclosure. 8.0 ELECTRICAL DESIGN FEATURES 8.1 All industrial controls and instrumentation will be housed in a free standing, NEMA 12 ventilated control cabinet. Full opening hinged doors should provide complete access to the control wiring and rear (sub panel) components. 8.2 The enclosure??s door will be interlocked with a disconnect switch for personnel safety. 8.3 Ammeters and voltmeters are to be provided on the front door to show heating element power balance and power draw to the hot zone. 8.4 An audible alarm will provide indication of cycle completion and system faults. 8.5 Emergency push to stop mushroom type "panic" button will be located on the front of the cabinet. 8.6 All control components will operate on 115 volt, single phase, 60 Hertz through an integral transformer. 8.7 Programmable Logic Controller (PLC): Allen Bradley Micrologix 1500. Also include a Touchscreen with diagnostic messaging such as an Allen-Bradley Panelview 1500 which provides operational and maintenance diagnostic messages. 8.8 Programmable Controller: Honeywell DCP551 for temperature and timing sequencing capable of storing up to 99 programs. 8.09 Honeywell Model UDC2500 for over temperature protection. 8.10 Eurotherm Graphic Digital Display Recorder, 12.1" Hi-Res Color Touch screen Display, 16-Channel, with Advanced Data Archiving will be included. 8.11 Vacuum Gauge Controller: Televac Model MC300 for measuring, monitoring and controlling the vacuum pressure down to 10-6 Torr range. One (1) cold cathode sensor and two (2) convection gauge sensors will be provided. 8.12 Control Thermocouples: Two (2) Type "S" for control and overtemperature protection will be supplied. 8.13 Work Thermocouples: Twelve (12) Type "K" thermocouples with hi-temp male plugs will be provided and will be internally mounted. A twelve-position plug and jack assembly will also be mounted on the control cabinet for calibration purposes. 8.15 MAIN DISCONNECTS The main and hot zone disconnect switches are to be supplied by the customer. 8.16 GUARANTEED SOAK ?? Guaranteed soak is required to provide a response to different load conditions. This feature should delay the heat cycle until selected work thermocouples are within a preset deviation band with respect to the furnace control thermocouple. Activation of this event causes the system to "hold" until all of the pre-selected work thermocouples are within a set deviation band. 8.17 SAFETY & INTERLOCK DESIGN ?? To avoid damage to the furnace system, the electrical control system should incorporate a sequencing protection feature in its design. ?? All vacuum valves should close and all pumps and motors should de-energize should a power failure occur with manual re-started upon restoration of power. ?? Should loss of cooling water occur, the hot zone and diffusion pump will be automatically de-energized. 9.0 TEST PROGRAM 9.1 The manufacturer will perform complete factory testing of the equipment. All tests will be recorded and results provided to us. Included in the furnace check-out procedure are: ?? Electrical cabinet and component check ?? Furnace leak check ?? Ultimate vacuum pressure ?? Operation of pumping system including valves ?? Operation of gas system including valves ?? Safety interlock systems and alarm functions ?? Recording of serial numbers from the vacuum pumps and gas blower ?? All functions activated by the programmer and all other vacuum components will be tested. ?? In addition to the above test criteria the manufacture will run a complete cycle and provide full vacuum, leak rate and temperature performance and report these results in light of the requirements. Work thermocouples can be refrasil insulated Type "K". Temperature uniformity testing can be limited to 2100?X F due to limitations of the Type "K" work thermocouple. ?? Backill and partial pressure system operation will be performed including cooling rate and these results will be reported in light of the requirements. ?? General training on the operation of the equipment should also be included. This purchase order is being issued to Solar Atmosphere Manufacturing Inc because the NETL Albany needs to purchase a horizontal loading vacuum furnace to support its Solid Oxide Fuel Cell Project and its Advanced Research Program projects. The Solar Model Solar Manufacturing Model HFL-2624-EQ vacuum heat treating furnace is the only furnace that is designed with graphite heating elements mounted cylindrically in the hot zone and divided into multiple trim zones and segments for ease of replacement of element replacement. This is a great cost saving advantage preventing the total element replacement by allowing for replacement of just the localized failed area. More importantly the heating elements supports are designed in such a way to shield the ceramic insulators from the build up of metal plating that can cause arcing and shorts because these designs are covered by three Solar-held patents. This is a critical aspect of the vacuum furnace design that makes the Solar furnace much safer. In the past other furnaces at the site have failed because of metal build up around the base of the heating elements causing a dangerous short which is unsafe and very expensive to repair. The Solar design protects against this occurrence. All responsible sources may submit a bid, proposal, or quotation which shall be considered by this agency. All interested firms must respond to DE-RQ26-06NT00914. Offerors shall provide sufficient technical literature, documents, etc., in order for the Government evaluation team to make an adequate technical assessment of the quote as meeting technical acceptability. Therefore, no solicitation will result with this announcement. This award shall be made using FAR 13, Simplified Acquisition Procedures. The North American Industry Classification (NAIC) is 339111. Request for information should be addressed to Mr. Robert L. Mohn, FAX 412-386-5770. The Technical Representative for the above requirement is Mr. Paul Turner, PHONE 541-967-5863. All bids, proposals, or quotations must be submitted by 5:00 PM Eastern Time, September 20, 2006.
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- Record
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