Specification for Combustion Infrared Carbon Sulfur Analyzer
I.Scope
A.The Combustion Infrared Carbon Sulfur Analyzer unit described in this specification is for use in performing quality control analyses using calibrated analytical programs, as well as analyses for which certified standards are not available. Therefore, the specification below addresses various design and construction considerations, and is consistent with a high quality production control instrument, that will also be used for both product evaluation and research applications. Stability, ruggedness, sub-system component design, and vendor support capabilities will be evaluated consistent with items found in ASTM E1019, along with current ISO 9000 and envisioned laboratory production analysis requirements. The instrument and vendor selected shall meet or exceed the following
1.General Instrument Architecture
a)The Total Carbon by the Combustion Instrumental Measurement Test Method is to be consistent with those described in ASTM E1019 Section 11 using infrared Absorption for the detection of carbon as related to CO2. Range of concentration for analysis of steels must be
capable of quantifying samples from a minimum concentration of 0.005 to at least a maximum of 4.5 total carbon in Steel when calibrated versus reference standards.
b)The Total Sulfur is to be determined by the Combustion-Infrared Absorption Test method consistent with ASTM E1019 Section 56.
c)Instrument must cover test methods for the determination of total sulfur as SO2 content in the range of 0.002 % to 0.35 % when calibrated versus reference steel standards. Samples are combusted in a stream of oxygen that converts the elemental form to oxide then streams the
combustion gas to the detector for quantitation by infrared absorption. Unit shall be capable of analyzing both carbon and sulfur concentrations simultaneously.
d)The vendor must be ISO (International Standards Organization) 9001 certified, and offer on site and remote support as specified. Vendor shall state individually the ISO certification date production facility, and for the locally based support organization.
e)Detectors
(1)Detectors shall be supplied as solid-state infrared for both carbon and sulfur with no moving parts. The detectors shall also be independently heated in order to thermally isolate them from environmental temperature fluctuations.
f)Gases
(1)Incoming carrier gas shall support the use of a heated copper oxide for improved carbon results. Back pressure of gases must be controlled to +/-0.05 mm Hg (absolute).
g)Detector Linearity
(1)The manufacturer shall specify the maximum intensity that each detector can accept while maintaining a linear response.
h)Power Requirements
(1)Must be able to operate under full load from 195 to 255 volts.
i)Sample introduction/presentation System
(1)The sample introduction/presentation system sample changer shall accommodate a standard size crucible. The sample changer must accommodate from 1 up to 60 samples. Sample changer shall be capable of moving specimens loading them into the analyzer entry point and removing them for disposal at the completion of the analysis. The sample changer shall have a minimum of 60 positions. Software shall be provided to allow the unit to run without operator intervention once programmed. Software must be capable of being programmed for automated startup and shut down.
j)Sample Crucibles
(1)Crucibles shall be supplied and be compatible with the system that may be preheated in a suitable furnace for not less than 40 minutes at approximately 1000°C shall be supplied for use with the unit. Crucibles must not contribute appreciable amounts of either carbon or sulfur to sample measurements after preheating and cooling in a clean environment.
k)Internal Spectrometer Environmental Control Requirements
(1)The spectrometer environment shall be within a temperature-controlled cabinet with optimum design for thermal, mechanical and electrical isolation. The overall design of the instrument shall be consistent with the most rigorous operational considerations and will be evaluated both from specification and from references within the user community.
l)Data Processing Computer
(1)A data processing computer shall be supplied for the instrument. The unit shall have the following equipment or equivalent. Computer equipped with 64 bit operating system, running Microsoft Windows 7 or newer. Instrument must contain real-time service diagnostics including ambient charts of instrument temperatures, pressures, and detector signal, manual control of solenoids and switches, automated leak checks, along with network and communications diagnostics. System computer ideally may be configured to accept scale values from a separate scale used for weight of crucibles with accelerator catalysts and sample additions.
m)Software Requirements
(1)The software must dynamically display average, standard deviation, and relative standard deviation. The instrument software must support both independent multipoint calibration and blank for each infrared detector. Drift correction of these independent multipoint calibrations must also be supported. Instrumental software must contain an automatic system check that verifies internal network connections, solenoids and switches, system pressures, furnace control and temperature.
n)Installation Related Sub-Systems
(1)A complete list of other pre-installation requirements shall be furnished with a bid response. These shall include, but are not limited to: ambient room temperature, vibration, electric supply stability, and power requirements. Vendor shall provide delivery and installation of the system. Purchaser will provide plumbing, electrical and HVAC requirements.
o)Remote Support Capability
(1)The instrument design shall incorporate advanced remote support features. Instrument vendor must provide remote service diagnostics with separate software package that is designed to connect the user with the instrument vendor’s service personnel.
p)Field Support
(1)Available services and infrastructure shall include service engineers located within 300 miles of Harrisburg, PA. Bidder shall state location of local U.S. office with dispatching center, and location of service engineers. The instrument vendor must provide direct manufacturing and sales/support of their product from the United States of America.
q)Application Support
(1)Available application support shall include at least one application specialist familiar with ferrous and nonferrous metals applications. In addition, support of geological, coal, glass, cement and polymer analysis for carbon and sulfur elemental analysis is desirable. Application support shall include both telephone and PC anywhere remote capabilities and be provided free of charge for a period of 2 years. Software upgrades must be provided free of charge if any new versions are introduced within one year of final acceptance and payment.
r)Consumables and Spare parts
(1)A list of all needed spare parts and consumables and order number information will be supplied. All spare parts and anticipated for operation of the unit for a period of 6 months shall be provided. Consumables needed for initial setup and demonstration of instrument performance shall be provided at time of installation. The Department anticipates running a minimum of 300 samples in a 6 month period of time.
2.Related Service
a)Installation
(1)The bid of Carbon Sulfur Analyzer and accessories shall include an installation and a site survey. Vendor shall supply purchaser with all needed information related to utilities and modifications of the delivery site to accommodate the unit. All parts, cablings, harnesses, leads, wires, processing boards, and accessory items etc. shall be provided for normal operation at no extra charge.
(2)The successful bidder must provide onsite installation of the system (set-up, assembly, calibration, computer program testing) by a qualified technician or engineer. The successful bidder must demonstrate full functionality of the equipment and systems for all test methods listed in Section 1.a.1.a and b of this document to the Department as part of the system setup.
b)Training
(1)The vendor shall provide operator and application on site (at least 1 day). Access to remote training of at least .5 days over the Internet shall also be provided.
(2) Training must not be initiated or proceed until installation of all system components and software are complete and full functionality of the equipment and systems for all test methods listed in Section 1.a.1.a and b of this document have been demonstrated to the satisfaction of the Department. Steel samples will be provided by the Department and shall be tested with the system to produce results consistent with the known acceptance ranges for both carbon and sulfur. The Department reserves the right to reject the equipment at no cost if results obtained do not prove to be accurate while meeting the repeatability and reproducibility requirements of the appropriate tables from ASTM E1019 for the material and element of interest.
(3)The successful bidder must provide a minimum one (1) business-day of equipment test training sessions for an unlimited number of employees by a qualified technician or engineer who is familiar with the installation and operation of the equipment. This training is to be included with the purchase price of the Combustion Infrared Carbon Sulfur Analyzer test system. The Department may video all training sessions for internal future use.
(4)Training must include the following:
- Set up of equipment, connections, etc.
- Preparation and handling of samples along with accelerators and crucibles for analysis.
- Setup of auto-sampler and programing of calibrations.
- General operation ofinstrument.
- Trouble shooting of system leaks, detector voltages and other maintenance functions such as cleaning of furnace components and replacement of expendables.
- Operation of test control software including:
- Changing units, Control modes and data entry
- Standard test set-up and operation.
- Specimen set-up.
- Zeroing sensors and curves and recalibration.
- Standard testing.
- Operation of test reporting software (Test result reporting, error correction, graphing,final report output).
- Hardwarecare and gas flow and filter maintenance.
- General program and hardware troubleshooting.
- Development of 'set-up' files for common tests including:
- Develop programs for both carbon and sulfuranalysis of steel and iron.
- Develop input parameters appropriate for concentration ranges.
- Review of hardware and software
(5)Trainings must take place at the Department’s Material Testing Lab located at 81 Lab Lane, Harrisburg, PA 17110.
(6)Training must take place immediately after setup and proper operational demonstration and verification is complete.
(7)Training must be directed towards an audience of operators who will be operating the apparatus and will be using the data generated from testing.
c)Warranty and Support
(1)The Carbon Sulfur Analyzer shall be warranted for one year for all parts and labor beginning upon instrument acceptance. Spare parts shall be available for all systems for at least a period of not less than 12 years from the date of purchase. Consumables shall be available for all systems for a period of not less than 12 years. Service shall be provided within 5 business days on site. In the event that repairs require off premises attention the vendor is to provide loaner equipment during the repair period.
(2)If problems, errors, or omissions are discovered where the system fails to function properly, the successful bidder, at the bidder's expense must provide appropriate replacement components, software modifications and re-issues, or other applicable corrections at their expense for the 12 months (1 year) from date of installation.
(3)All parts must be completely functional and free of defects upon arrival. Additionally, the system must be functional and free of defects observed in the first 1 year of system use (after complete installation and setup by the successful bidder).
(4)Failed components must be replaced in a reasonable amount of time. This time must not exceed 30 days.
(5)All warranty repairs must be done either off-site or on-site at the location of installation where practical. If comprehensive system diagnostics, major component cleaning or replacement, or other major operations requiring specialty work-benches, additional computer equipment, or several staff members are required, the system must be returned to the manufacturer for work of this nature. When any system or component needs to be repaired at another location all packaging and shipping costs are the responsibility of the successful bidder.
(6)If components or the entirety of the Combustion Infrared Carbon Sulfur Analyzer system that has been purchased are discontinued by the successful bidder, then the successful bidder must notify the Department within 30 days.
d)Warranty RF Power Tube
(1)Warranty provisions for the RF power tube shall be a minimum of 2 years without limitation for hours of use. This warranty must also apply to replacement tubes that may be purchased.
e)Warranty Infrared Detectors
(1)Warranty provisions for the Infrared Detectors supplied shall be a minimum of 2 years without limitation for hours of use.
f)Service Purchase Information
(1)Service purchase agreement information for the second through forth years of ownership shall be supplied to the purchaser upon bid. Purchaser shall have the entire one-year warranty period to accept or decline the agreement. Pricing shall include an option for coverage of all major systems with and without parts supplied, preventive maintenance (including cleaning of all optics), annual preventive maintenance checks and service turnaround coverage time options.
3.Safety Features
a)Interlock System
(1)A safety interlock system shall be provided to protect the user from harmful exposure to RF radiation. The interlocking system shall shut down power to the RF tube if access is attempted.
b)Radiation Safety
(1)Instrument must meet all Federal, State and local radiation protection requirements. Safety interlock check procedures must be provided with the instrument.
c)Manuals
(1)Manuals for repair and safe operation of the unit and all components shall be supplied in English. Manuals containing application information for the analytical software shall also be provided. Complete part lists, and exploded diagrams of all components shall be provided.
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