300 kW EB Melting Furnace

SCOPE OF WORK
1.0 GENERAL SCOPE OF WORK:
The scope of supply includes all the sub-systems, components, bought outs etc.
required for the satisfactory performance of the EB Melting Furnace. The design
of the system except for the EB Gun and Power supply is included in the scope
of the vendor, hence the comprehensive list of supply shall be drawn by the
vendor in the PartI submission. The scope of work also includes any other items
required to meet the performance or statutory requirements.
Following gives some major activities covered under the scope of work.
1.1 MECHANICAL:
To
prepare the final design reports and design drawings for all
subsystems/components. The scope includes strength design as per codes,
thermo-mechanical design and analysis of all heat facing components,
analysis of out of code designs, vacuum design (vacuum calculations, pump
selection, expected pump down and holding times, differential vacuum
between work chamber-intermediate chamber-gun chamber and vacuum
profile etc )
To prepare fabrication drawings based on the approved design drawings
and design report.
Submission of fabrication/shop drawings for approval.
Submission of site preparation (civil) drawings for erection/commissioning at
NFC.
Preparation and submission for approval of
1.
2.
3.
4.

Manufacturing Procedure Specification (MPS)

Manufacturing Process schedule
Quality Assurance Plan (QAP)
Quality Control Procedure (QCP)

Preparation

of Bill of Materials
Submission
of specifications and source of standard bought out
components/equipment.
Submission of specifications of components planned to be sub contracted.
Purchase, procurement, testing and identification of material as per the Bill of
Materials and material specifications.
Purchase, procurement and performance testing of standard bought out
components / equipment.
Fabrication as per the approved MPS
Stage wise inspection as per the approved QAP & QCP.
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1.2 ELECTRICAL:
Preparation

1.
2.
3.
4.
5.

Electrical Drawings of the various subsystems

GA Drawings of the Control Cubicle and control console
GA Drawings / Routing of the Electrical Wiring
Purchase specification for bought out items
QAP Plan / Testing Procedure

Design

1.
2.
3.
4.

and submission for approval of

of control and instrumentation for

Vacuum system
Feeder and crystallizer Handling system
Integrated Control Console
Software for the PLC system

Stage

wise inspection as per the approved QAP

1.3 GENERAL:
Component

performance testing as per the testing clause.

Assembly of the EB Furnace at contractors shop.
Performance testing of the assembly as per testing clause
Modifications, if any, required for satisfactory performance.
Preparation of as built drawings and revised design reports.
Disassembly of the system, packing and forwarding to BARC site.
Civil work at site related to the erection and commissioning of the system at
BARC.
Cooling water piping work from supply / return header.
Installation of Rotameters, Flow switches and RTDs coming on water lines
(including cabling).
Installation of HVDC power cable and its termination
Installation of power cable from the distribution box to panel and their
termination
Erection and Commissioning of the system at BARC.
Performance testing of the assembly as per testing clause.
Modifications, if any, required for satisfactory performance.

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1.4 DOCUMENTATION:
Following documents are required to be submitted for purchasers approval
before taking up material procurement and fabrication:
Mechanical:
1) Design report and design drawings for all the sub-systems
2) Fabrication drawing based on approved design reports and design drawings
3) Layout of EB melter system including control panel with major dimensions
4) Layout of Vacuum systems with major dimensions
5) List of materials with detail specifications
6) List of materials to be imported with detail specification
7) Manufacturing Procedure Specification (MPS)
8) Manufacturing Process schedule
9) Quality Assurance Plan (QAP)
10) Quality Control Procedure (QCP)
11) Civil information drawings
12) Utility requirements and its connection details with EB melter and piping
Electrical:
1) All design details, schematic diagrams, circuit diagrams along with
functional details.
2) List of materials giving type number and make of all components used.
3) Mechanical dimensions & estimated weight of control cubicle and
operators control desk.
4) Inside layout diagrams of the components in the control cubicle.
5) List and type of I/O and display requirement in main control system
6) Testing schedule and details of all the tests to be carried out.
Three sets of following approved documents (both hard copy and soft copy)
shall be made available to the inspector visiting the contractors shop for pre
dispatch clearance of the complete assembly:
(1) As built drawing of all the sub-systems of the complete assembly
(2) Revised design report
(3) QA/QC report
(4) Performance test procedures
(5) Performance test reports
(6) Detailed electric/electronic circuit diagrams
(7) Hard and soft copy of the PLC program
(8) Operators manual for day to day operation and troubleshooting
(9) Instruction manual for future servicing work
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The system will not be cleared for dispatch without these documents.
1.7 Important Points:
The

set of drawings supplied with this document are conceptual design

drawings. Contractors are requested to study them properly and prepare final
drawings for approval taking into account detail design changes, material
sizing and its availability. The dimensions of the components are subject to
confirmation on detail component design during the detail design stage.
Some minor modification in the positioning of the flanges or addition of one or
two additional nozzles etc. may be expected due to design calculation.
Contractors shall carry out these minor variations without requesting it as an
additional scope of work.
Sub-contracting of part of the work quantum shall need purchaser's prior
approval
Selection of standard units to be used in the system will need purchasers prior
approval
Any import of material/equipment will be arranged by the contractor alone
and shall not be referred to the purchaser for end use certification
Contractors shall obtain approval of BARC for the third party inspection
agency for the tenure of the project.
Appointment of Design agency for detailed engineering design and drawings
shall be approved by BARC prior to submission of design drawings.
Three sets of approved documents (as per sub section 1.4) shall be made
available to the inspector visiting the contractors shop for pre dispatch
clearance of the complete assembly. The system will not be cleared for
dispatch without these documents.
2.0 Warranty and Annual Maintenance:
Contractor

shall provide full warranty for all the items included in the scope of
supply for a period of 12 months from the date of successful installation and
commissioning at purchasers site.
Annual Maintenance shall be provided for five years after expiry of the
warranty period at the rate quoted by the contractor in the original price bid.

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Design and Testing Details

I. MECHANICAL:
1.0 DESIGN AND TESTING REQUIREMENT

1.1 GENERAL DESIGN BASIS:

The components / sub-systems involved in this equipment are of multidisciplinary nature. The following information given is to be followed wherever
applicable. For sub-systems / components where it is not applicable contractor
shall produce suitable documents and detailing procedure for design, testing
and approval of BARC.
The system can be described as a high vacuum clean environment system. The
base and operating pressures of the system will be in the range of 5x10-6 mbar.
The work chamber and doors are water-cooled. The external cooling water
pressure of 5 kg/cm2 (in addition to internal vacuum) is a parameter for the
design of the work chamber. One melting operation is expected to take about
10 minutes of hot run. The crucible is designed to take care of about 6 kW heat
load while the work chamber is designed to handle 9 kW/m2 heat flux.
General Design Features:
Design External pressure for inner shell/dish 6 kg/cm2
ends/flat ends
Cooling water pressure
5 kg/cm2
Design internal Pressure for outer jacket/dish 5 kg/cm2
ends
510-6 mbar
Working Vacuum Level
*Design temperature
1500 C
Gasket material
Viton
Shell material
SA 240 304L
Flange material
SA 182 F 304L
Nozzle material
SA 312 TP 304L
Support material
Structural Steel
Max. allowable Cooling water pressure drop
2.5 kg/cm2
Cooling water temperature rise
100 120 C
*The design temperature for the work chamber and gun chamber is arrived at
after taking sufficient margin on the maximum temperature which it can see
during the electron beam melting operation. This does not mean that the work /
gun chamber wall is always exposed to that temperature. This more
appropriately refers to the spot temperature due to bombardment/ leakage of
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stray electrons over a small area. The design temperature may be considered as
about 800 C. Appropriate design of the heat shield packs will ensure the safe
working temperatures.

1.2 CODES AND STANDARDS:

The following codes in their latest edition, including addenda at the time of
bidding shall form the basis for design, fabrication, inspection, testing and
acceptance of equipment.
a) ASME Boiler & Pressure Vessel Code Sec. VIII Div.1 and 2
b) ASME Boiler & Pressure Vessel Code Sec. V
c) ASME Boiler & Pressure Vessel Code Sec. IX
2.0 MATERIAL SPECIFICATIONS:
Material to be used shall conform to:
a) ASME Boiler & Pressure Vessel Code Sec. II
Stainless Steel Seamless Pipes: SA312, AISI 304, 304L, 316, 316L
All the pipes shall be subjected to intergranular corrosion test as per ASTM
A262 practice A; if the result is not satisfactory, then the acceptance shall
be on the basis of practice E. For certain nozzles, if seamless pipes are not
available, welded construction from plate / sheet may be allowed.
However, in such cases weld seams shall be subjected to 100%
radiography.
Stainless Steel Plates: SA 240, AISI 304, 304L, 316, 316L
All the plates shall be subjected to intergranular corrosion test as per ASTM
A262 practice A; if the result is not satisfactory, then the acceptance shall
be on the basis of practice E.
Stainless Steel Forgings: SA 182, F 304, 304L, 316, 316L
All the forgings shall be subjected to intergranular corrosion test as per
ASTM A262 practice A; if the result is not satisfactory, then the
acceptance shall be on the basis of practice E. All the forgings / flanges
shall be tested ultrasonically for cracks, laminations, porosity and other
inclusions in accordance with SA 435 and supplemented by SA 577 of
ASME Boiler and Pressure Vessel Code Section V.
Oxygen Free Copper (OF Copper):
ASTM Specification designation: SB 187 / SB152
UNS No.: C10200
Temper Required: O60
The forging and heat treatment of the copper block shall be done as per
the approved procedure. The properties of the OF Copper shall be as per
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the above-referred specifications. Testing of the forgings shall be

performed by a mutually agreed reputed testing agency as per ASTM
standards at the source point itself if it is procured indigenously. If it is
imported, it is the responsibility of the vendor to arrange for the testing of
the material at a mutually agreed reputed testing agency. This includes
the OFE Copper plate used for explosion bonding.

Chemical analysis of the copper shall be performed to confirm the

contents of copper after forging and heat treatment process. The copper
shall also be tested for the contents of the impurities like oxygen, sulphur,
phosphorous etc.

Elevated temperature Mechanical Tensile test (at 200 0C) of forged and
heat treated OF copper as per ASTM E 21 shall also be carried out in
addition to the room temperature tensile test.

The test coupon drawn from the main block of the OFE copper block shall
be placed along with the main block for heat treatment (annealing). In
addition to the tensile test mentioned above the tensile test of the test
coupon (in as annealed condition) which will be placed inside the
furnace during annealing of the main block shall also be carried out.

The forged OFE block and the OFE copper plates shall be subjected to
ultrasonic testing for cracks, laminations, porosity and other inclusions in
accordance with SA 435 and supplemented by SA 577 of ASME Boiler and
Pressure Vessel Code Section V. Machined copper surface to be tested
for surface defect by Dye Penetrant test.

Tungsten > 99.9% pure; (Supplier: M/s Plansee, Bangalore)

Bolts, Studs and Nuts: SA 193, B8
Gasket: Viton of Shore Hardness 655 (Testing as per ASTM D 1414-78)
2.1 MANUFACTURING PROCEDURES:
The specifications mainly deal with manufacture of pressure vessel as per ASME
BOILER & PRESSURE VESSEL CODE. There are some components in the total
scope of work, which do not fall in the category of pressure vessels.
Nevertheless, wherever possible procedures for material identification,
inspection, fabrication, welding requirements, radiography, testing and
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assembly will be followed as per clauses discussed under these headings. In

addition to standard code practice, the following important vacuum practices
will be followed in the design, fabrication and assembly of the EB melter.

The mating and free surfaces of the components are required to be

absolutely clean without any traces of oil or grease.
The inner surface of the chamber, port necks, plumbing etc. is to be
buffed and polished.
Weldments inside the vacuum environment will have passage for trapped
gases.
Surfaces in face to face contact will have provision for passage of
trapped gases.
Bolts used inside the vacuum chamber will have through and through
hole for passage of trapped gases.
Crevices of any kind inside the vacuum chamber will be avoided at any
cost.

2.2 MATERIAL INSPECTION & IDENTIFICATION:

Documents required as per the code. We reserve the right to ask for performing
tests on the test specimens and coupons in addition to the manufactures test
reports. It will be contractors responsibility to conduct required tests at a
reputed test agency. Standard stamping and stamp transferring procedures will
be followed for the identification of the material.
Testing procedures for standard bought out components/equipment will be
drawn as per the type of the component and the details of which will be
worked out during the execution of the work.
3.0 FABRICATION AND WELDING REQUIREMENTS:

All the fabrication shall be in accordance with approved shop fabrication

drawings and MPS and shall confirm to ASME BOILER & PRESSURE VESSEL
CODE Section VIII DIV.1. The fabrication drawings will indicate clearly (1)
Tolerances on machined/fabricated parts, (2) Tolerances on subassembly, (3)
welding symbols and weldment details, (4) Pre and post weld heat
treatment, (5) Detail welding procedures
Purchasers written approval of Fabrication /shop drawings, manufacturing
procedures, welding procedures, welders qualification etc. shall be
obtained by the contractor prior to the commencement of the fabrication.
All full penetration butt welded joints shall be subjected to 100% radiography.
Plasma cut edges shall be ground by contractor as required to remove slag,
detrimental discoloration and non uniformity of edges.
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All pressure bearing butt welds shall be full penetration welded joints. All
pressure boundary joints shall be welded by GTAW welding process. SMAW
welding process may be used for welding of structural members. Backing
strip may be used only after receiving prior approval from Owner.
Nozzles, Manways and their reinforcing pads shall be attached to Equipment
with full penetration welds.
Weld edge preparation, Weld joint design and other welding techniques
shall be so selected as to minimize distortion and keep heat input to the
minimum required
All main welds seams shall be clear of nozzles, manholes and stiffening rings.
Other attachments like reinforcing pads, internals, supports, cleats etc. shall
preferably be away from the main seams. In case it is unavoidable, the main
seam coming under the attachment plus 150 mm length on both sides shall
be ground flush, fully radiographed and dye penetrant examined before
welding any such attachment. All such welding would require prior approval
from purchaser.
Only welders which are qualified for the accepted procedure shall be
employed.
Contractor shall submit welding procedure specification and qualification
record to Owners inspector or authorized representative for approval.
Welding consumables shall be as per ASME Boiler & Pressure Vessel Code
Sec. II Part C and shall be indicated in fabrication drawings.
Ferrite Number on weldments shall be within 5 - 10. The weld consumables
and raw material shall be selected accordingly. This shall be demonstrated
during weld qualification and on actual weld seams
Dye Penetrant test shall be done for all weld jo ints, for root pas s
as well as finish weld pass.
All welded joints are to be subjected to mass spectrometer leak detection
test for an individual leak of 10-8 standard cc/sec. Spots showing leaks above
the specified limit will be repaired and subjected to radiography and MSLD
tests.
Welding qualifications shall be as per ASME Boiler & Pressure Vessel Code
Section IX
Suitable fixtures to minimize welding distortions and excessive residual stress
will be designed and manufactured by the contractor. Such welding
techniques as balancing distortions by sequencing, pre-setting, minimum
necessary current selection etc. will be suitably adopted to achieve required
dimensional tolerances

4.0 INSPECTION:
Contractor shall provide all testing and inspection services and facilities (in
house or from a mutually agreed reputed testing laboratory). The inspection and
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testing will be conducted in a manner satisfactory to and shall be subject to

quality surveillance of the purchaser. Welding procedures and performance test
(welders' qualification) shall be conducted in a manner satisfactory to the
purchaser and in accordance with the provisions of ASME BOILER & PRESSURE
VESSEL CODE Section IX. Contractor shall submit Manufacturing Procedure
Specifications (MPS) and Quality Control Plan (QCP) for approval. The MPS and
QCP documents shall clearly indicate Sampling Points / Witnessing Points / Hold
Points offered to Purchasers QS. This should also list, in proper sequence, all
manufacturing stages and inspection stages. Detailed test procedures for the
various NDT techniques proposed to be followed shall be submitted for
approval.
The broad stages of inspection are
Material

inspection, testing and identification

Approval of fabrication/shop drawings, manufacturing procedures, welding
procedures, welders qualification etc.
Stage inspection including inspection of machined parts prior to welding
Weld Edge preparation including visual check for laminations
Alignment of Longitudinal seams
Rolling tolerances on individual sections
Alignment of sections
Root Pass clearing before welding
Nozzle Setting
Inspection of welded subassemblies/assemblies in stages
Dimensional Check
Dye Penetrant examination
Radiographic Examination
Stress relieving / Solution Annealing
Calibration record of measuring instruments
Leak testing of the equipment by MSLD at shop and Site
Hydrostatic Pressure test at Shop and at Site
Proof Hydrotest / Pneumatic test of the Crucible assembly
Any other special test such as corrosion, hardness, iron contamination test
etc.
Performance testing of the Complete Assembly at shop and at site
Inspection of standard bought out components/equipment
Inspection of sub contracted components before accepting the delivery
It shall be mandatory for the contractor to submit the complete schedule of
procurement, manufacture, inspection and testing for the approval of the
purchaser. It shall also be mandatory for the contractor to keep a complete
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record of the activities including internal QC/QA records and produce them for
the purchaser's scrutiny as and when demanded.
5.0 TESTING AND ASSEMBLY:
Contractor shall submit detailed Acceptance Test Plan (ATP) for approval. This
shall list in proper sequence all the assembly and testing stages with detailed
test procedures.
5.1 STANDARD DIMENSIONAL CHECK:
The complete assembly of the components covered under the scope of this
document will be subjected to standard dimensional and orientation checks
after the final machining (prior to welding), after the welding and at assembled
condition.
5.2 STANDARD HYDROSTATIC TEST:
The standard hydrostatic test will be performed as per the relevant clauses of
UG-99 of ASME BOILER & PRESSURE VESSEL CODE Section VIII Div.1. The
vessel/component will be held at the test pressure for minimum of 30 minutes.
Inspection shall be made of all joints and connections at applied pressure not
less than 1.3 times the design pressure. Clean potable water with chlorine
content not more than 300 ppm will be used as testing medium.
Standard procedures for flushing out air and mounting locations of the
pressure gauges will be followed.
5.3 PROOF HYDROSTATIC TEST:
The crucible assembly shall be proof hydrotested as per design code. The
crucible assembly shall be held at the test pressure, which is three times the
design pressure for minimum of 30 minutes. Inspection shall be made of all joints
and connections at applied pressure.
5.4 STANDARD PNEUMATIC TEST:
The standard pneumatic test will be performed as per the relevant clauses
of UG-100 of ASME BOILER & PRESSURE VESSEL CODE Section VIII Div.1. The
vessel/component will be held at the test pressure for minimum of 30 minutes.
Inspection shall be made of all joints and connections at applied pressure not
less than 1.1 times the design or, the maximum working pressure.
5.5 VACUUM TESTING:
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Prior to vacuum testing the components will be inspected for the surface finish,
passage for entrapped gases, flange finish (tool marks, scratches running across
the O ring groove), inclusions, oil/grease stains etc. from the vacuum
compatibility point of view.
All the sub systems like work chamber, internals etc. will be individually subjected
to vacuum level of 5x10-3 mbar. The sub-assemblies will be leak tested with mass
spectrometer leak detector for an individual leak tightness of 1x10-8 standard
cc/sec. On clearance of individual components and sub assemblies the system
including all the sub-systems will be leak tested with mass spectrometer leak
detector for an individual leak tightness of 1x10-8 standard cc/sec.
Valves:
All the individual components of the plumbing line including valves shall
be leak tested using MSLD for leak tightness of better than 110-8 std.
cc/sec. There shall not be any leak above 110-8 STD cc/sec. Leaks
above 1x10-8 STD cc/sec shall be rectified and repeat MSLD testing has to
be carried out.
All the valves shall be tested using MSLD for body leak as well as proper
sealing of the seat flange by keeping one side under vacuum and the
other side at atmospheric pressure in both directions.
Pumping Module:
The vacuum systems shall be integrated with the work chamber and gun
chamber with all other sub-assemblies after completing the performance testing
of the pumping system. The integrated system will be exposed to atmospheric
pressure for a minimum period of 1 hour before starting the vacuum system.
Vacuum test shall be carried out for the work chamber and the gun chamber
individually keeping the isolation valve between the two in closed condition. The
ultimate vacuum, pump down and holding time shall be monitored as per the
following tables.
Vacuum Test for Work Chamber
PUMP DOWN
Vacuum
Level
Chamber in mbar

1
5 x 10-1
1 x 10-1
5 x 10-2
1 x 10-2
1 x 10-3
1 x 10-4

HOLDING TIME
Level
in Time in minutes from Vacuum
Chamber in mbar
cold start

in Time in minutes
pump shut down

5 x 10-6
1 x 10-5
1 x 10-4
1 x 10-3
1 x 10-2
5x10-1
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from

1 x 10-5
5 x 10-6
Vacuum Test for Gun Chamber
PUMP DOWN

HOLDING TIME

Vacuum
Level
Chamber in mbar

Level
in Time in minutes from Vacuum
Chamber in mbar
cold start

in Time from
down

pump

shut

1 x 10-6
5 x 10-6
1 x 10-5
1 x 10-4
1 x 10-3
1 x 10-2
5x10-1

1
5 x 10-1
1 x 10-1
5 x 10-2
1 x 10-2
1 x 10-3
1 x 10-4
1 x 10-5
5 x 10-6
1 x 10-6

5.6 Differential Vacuum Test:

The isolation valve in between the gun chamber and the Work chamber shall be
opened. Roughing operation in both the chambers shall start simultaneously. On
reaching respective roughing vacuum the high vacuum valves shall be opened.
The pump down ramp shall be monitored as per the following table:
Pump
down
time

Vacuum in Work
chamber

Vacuum in
intermediate
chamber

Vacuum in gun
chamber

Gas will be supplied in the work chamber and intermediate chamber at a

controlled flow rate via mass flow controller. The vacuum in the gun chamber
and the intermediate chamber will be monitored in the following format:
Gas flow
Gas flow
Vacuum in
Vacuum in
Vacuum in
rate in
rate in
Work chamber
intermediate
gun chamber
work
intermediate
chamber
chamber
chamber
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Pumping module for all the vacuum systems shall be shut down simultaneously
and holding time shall be monitored as per the following table:
Holding time

Vacuum
chamber

in

Work Vacuum in gun chamber

5.7 Cyclic Testing:

Components and subassemblies designed to operate in cyclic mode shall be
subjected to cyclic testing for a specified number of cycles. The components
will be tested for its performance standard after the cyclic operation. Following
systems shall undergo the cyclic test:
All the pneumatic valves: Leak tightness of the valves shall be carried out
after about 100 cycles of operation.
Linear motion of the finger mould crucible
Circular motion of the ring / button mould crucible
5.8 Composite Test:
On clearance of the sub assemblies the system will be assembled and subjected
to a composite test in which the interior of the chamber and associated sub
systems and the water cooling passage will be simultaneously pressurized to their
respective maximum design pressures. The melter assembly will be held at
pressure for 30 minutes and standard leak tests will be carried out. The melter
assembly will be further vacuum tested (5x10-6 mbar) with all the internals in
position with cooling water passage pressurized to the design pressures. The
melter assembly will be leak tested with MSLD for an individual leak tightness of
1x10-8 standard cc/sec.
All the above tests are part of the performance testing of the melter and shall
be conducted at the shop and site.

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