M1 Coating and Cleaning Equipment Specification

Transcription

1 Project Documentation SPEC-0074 Revision A M1 Coating and Cleaning Equipment Specification Eric Hansen, Kerry Gonzales 18 February 2014 Prepared By: Approved By: Approved By: Released By: Name Signature Date Kerry Gonzales Sr. Opto-Mechanical Engineer Simon Craig Systems Engineer Tom Berger Project Scientist Joseph McMullin Project Manager K. Gonzales 19-Feb-14 S. Craig 04-Mar-14 T. Berger 31-Mar-14 J. McMullin 11-Apr-14

2 REVISION SUMMARY: 1. Date: 29 October 2007 Revision: Draft Changes: Initial Draft 2. Date: February 2014 Rev: A Changes: Initial Release SPEC-0074 Rev A Page ii

3 TABLE OF CONTENTS 1. SPECIFICATIONS OVERVIEW SCOPE OF THE DOCUMENT RELATED DOCUMENTS Related DKIST Project Documents Interface Control Documents and Drawings Verification Methods WORK BREAKDOWN STRUCTURE M1 COATING AND CLEANING EQUIPMENT DEFINITION M1 COATING AND CLEANING EQUIPMENT REQUIREMENTS & SPECIFICATIONS M1 WASH PLATFORM REQUIREMENTS & SPECIFICATION Overview M1 Wash Platform Functional Requirements & Specifications M1 Wash Platform Performance Requirements & Specifications M1 C&C SUPPORT REQUIREMENTS & SPECIFICATIONS Overview M1 C&C Support Functional Requirements & Specifications M1 C&C Support Performance Requirements & Specifications GENERAL REQUIREMENTS AND SPECIFICATIONS DESIGN AND ANALYSIS REQUIREMENTS & SPECIFICATIONS Drawings & Documents Requirements & Specifications Structural Design Requirements & Specifications Electrical Design Requirements & Specifications Maintenance Requirements & Specifications FABRICATION REQUIREMENTS & SPECIFICATIONS Materials and Workmanship Requirements & Specifications Stress Relieving Requirements & Specifications Surface Finish, Coatings, and Paint Requirements & Specifications PACKING AND SHIPPING REQUIREMENTS & SPECIFICATIONS SPEC-0074 Rev A Page iii

4 1. SPECIFICATIONS OVERVIEW 1.1 SCOPE OF THE DOCUMENT This document consists of the requirements and specifications for the development, design, analysis, procurement, fabrication, factory assembly, factory acceptance testing, disassembly, packaging, transportation, delivery, site assembly, and site acceptance testing for the DKIST M1 Coating and Cleaning Equipment. The Contractor shall be responsible for the detailed design, analysis, fabrication, pre-assembly, factory acceptance testing, delivery, site assembly and site testing of the M1 Coating and Cleaning Equipment and all of its subsystems as specified in this document. 1.2 RELATED DOCUMENTS Related DKIST Project Documents SPEC-0092, M1 Cell Assembly Specification SPEC-0020, M1 Coating Procedures and Requirements SPEC-0034, M1 Blank Specification (Zerodur) SPEC-0028, M1 Polishing Specification SPEC-0149, Haleakala Environmental Specification Interface Control Documents and Drawings It is the intent of the DKIST project to integrate and interface the M1 Coating and Cleaning Equipment with other DKIST subsystems, such as the M1 Assembly. The Contractor shall be required to interact and work periodically with DKIST Project personnel and outside vendors that are providing these related subsystems. The purpose of these interactions is to refine and manage required changes associated with the critical interfaces between the M1 Coating and Cleaning and these other subsystems, and to improve the overall design and performance of the DKIST. The M1 Coating and Cleaning Equipment shall provide interfaces for the following items that are not directly included in this Contract. These interfaces are each specified in their respective Interface Control Documents that are included as part of this specification: ICD M1 Assembly to Coating and Coating and Cleaning Equipment ATST-DWG M1 Wash Platform Assembly Interface ATST-DWG M1 Assy to Coating Chamber Interface ATST-DWG M1 Shipping Container Interface M1 Mirror SPEC-0074 Rev A Page 1 of 12

5 1.2.3 Verification Methods Included in each major numbered specification listed herein this document is a requirement verification method. These verification methods specify the minimum standards of verification required by AURA to ensure that the individual requirements and specifications are met. All verification activities are the responsibility of the Contractor; i.e., the Contractor shall be solely responsible for providing any and all test equipment, analyses, inspections, and other means necessary to verify that the specifications and requirements have been met. Examples of verification methods include: Design Review. Verification by design review shall mean that the Contractor demonstrates to AURA during the appropriate design review that the equipment shall meet the specification by way of its intrinsic layout and configuration. Analysis. Verification by analysis shall mean that Contractor analytically demonstrates that the design meets the specification. Such analyses may include finite element methods, computational fluid analyses, closed form analyses, etc. All analyses shall be provided to AURA in written report form, in both electronic (e.g., MS Word) and paper copy format. Inspection. Verification by inspection shall mean that the Contractor visually demonstrates to AURA personnel that the specification has been achieved on the as-built equipment during factory acceptance testing. Test. Verification by test &/or measurement shall mean that Contractor empirically demonstrates that the as-built equipment meets the specification. Testing may be required in the factory during factory acceptance testing and/or at the Site during Site acceptance testing. At a minimum, the specification compliance matrix provided by Contractor as part of the Work shall use the verification method(s) listed in each of the requirements sections below. All analyses, test results (with test error analysis) and other verification reports shall be provided to AURA in written report form, in both electronic (e.g., MS Word, Excel, or PDF) and paper copy format. For each Test method used for acceptance testing, the Contractor shall perform a test error analysis. All potential errors effecting the measurement shall be listed and their influence on the test results evaluated. The required measurement value shall be adjusted so the Test shall yield a 99% or greater certainty that the specification has been met after taking the test error analysis into account. SPEC-0074 Rev A Page 2 of 12

6 2. WORK BREAKDOWN STRUCTURE 2.1 M1 COATING AND CLEANING EQUIPMENT DEFINITION The M1 Coating and Cleaning Equipment shall be comprised of the following major systems, subsystems, and components. Specific details, requirements, and specifications of these items are specified in more detail later in this document. WBS Coating and Cleaning Equipment, Fixtures & Tooling Cleaning Station, Fixtures & Tooling includes the stripping, washing and staging equipment required to prepare the telescope mirrors for recoating. WBS M1 Wash Platform The M1 Wash Platform is the platform used to support and manipulate the M1 Mirror during the cleaning and stripping process. It provides personnel access to all M1 Mirror surfaces that require preparation prior to coating and captures effluent used in the cleaning and stripping process for later disposal. WBS M1 Coating & Cleaning Support The M1 C&C Support provides a nine point whiffle-tree type support frame for the M1 Mirror for use on the M1 Wash Platform and coating chamber. It provides lateral restraints for M1 safety in the event of earthquake, and guides to safely install the M1 using the M1 Lifter. SPEC-0074 Rev A Page 3 of 12

7 3. M1 COATING AND CLEANING EQUIPMENT REQUIREMENTS & SPECIFICATIONS Commonality of Designs Wherever possible, Contractor shall utilize identical equipment and designs throughout the M1 Coating and Cleaning Equipment. The purpose of doing this is to lower costs associated with design effort, spares, maintenance, and the like. To the extent possible, Contractor shall adopt designs used throughout the observatory for similar equipment to maximize commonality Reliability The lifetime of the DKIST telescope is expected to be in excess of forty years. The objective of the facility is to allow maximum telescope availability and performance for the given weather conditions of any day of the year. The remote nature of the site puts a premium on having robust systems that are easily repaired. Wherever possible, all assemblies, subassemblies, components, parts, and mechanical systems shall be designed to exceed the lifetime of the facility. Contractor shall identify any and all items not designed to exceed this lifetime, and maintenance procedures and spares lists shall be provided for them. Failure modes of all critical components shall be evaluated and the design of all systems shall be such that failure of a single component shall result in a minimal performance reduction of the system. Verification: Design Review Maintainability The M1 Coating and Cleaning Equipment shall be designed such that routine preventative maintenance will be completed in less than four hours per month. Repairs of all failures arising as a result of normal operations of the M1 Coating and Cleaning Equipment shall be accomplished in no more that 8 hours by trained personnel. The M1 Coating and Cleaning Equipment shall be designed to be maintained using standard tools and test equipment. Any special tools or equipment required for this operation shall be designed and furnished by the contractor, along with detailed instructions for their use. Friction and wear components not expected to provide reliable performance over the design lifetime shall be easily replaced. Servicing instructions shall include inspections of such equipment to evaluate conditions on a periodic basis. The M1 Coating and Cleaning Equipment design shall ensure that all necessary maintenance operations can be effectively carried out without risk to personnel or hardware. Special care must be taken in the design of any hardware that would require maintenance personnel working around the equipment to avoid risk to the M1 Mirror. SPEC-0074 Rev A Page 4 of 12

8 The Contractor shall provide all special tools and equipment necessary for initial set-up, maintenance, and servicing operations required throughout the operational life of the M1 Coating and Cleaning Equipment. This excludes common hand tools such as wrenches, sockets, Allen keys, etc. Custom stands, sights and instruments necessary for initial set-up of the system, debug, and regular maintenance shall be delivered as special tooling and equipment. Any special handling fixtures, such as spreader bars, necessary for handling parts of the M1 Coating and Cleaning Equipment shall be deliverable. Special tools shall be marked with the part number. For ease of installation, a lifting feature shall be provided for any removable subassembly having a mass exceeding 15 kg. Verification: Design Review, Inspection Stresses Stresses in all members shall be maintained within safe working values for all combinations of fabrication, assembly, operation and survival conditions. Unless specified otherwise, a safety factor of 4 on material yield strength shall be maintained under any combination of Operational and Survival Conditions for all components delivered as a part of this specification. Consideration of fatigue shall be given to all structural members and connections subjected to regular stress fluctuations over the lifetime of use. Verification: Design Review, Safety Chemical Compatibility The following chemicals are used as a part of the mirror stripping and cleaning process; (a) Hydrochloric Acid, (b) Cupric Sulfate, (c) Potassium Hydroxide, (d) Nitric Acid, (e) Ceric Ammonium Nitrate, (f) Calcium Carbonate, (g) Potassium Ferrocyanide solutions, and (h) Sodium Thiosulfate solutions. All component materials and coatings shall be compatible with incidental and prolonged exposure to these chemicals, within the design capability, for a period of time consistent with the anticipated time to complete the mirror stripping and cleaning process. Verification: Design Review SPEC-0074 Rev A Page 5 of 12

9 3.1 M1 WASH PLATFORM REQUIREMENTS & SPECIFICATION Overview Scope The M1 Wash Platform is the platform used to support and manipulate the M1 Mirror during the cleaning and stripping process. It provides personnel arms-length access, within 24 inches, to all M1 Mirror surfaces that require preparation prior to coating and captures effluent used in the cleaning and stripping process for later disposal. Verification: Design Review Location of Use The M1 Wash Platform shall meet its functional and performance requirements when used within the DKIST observatory facility or within the AEOS observatory facility (Class D environment as specified in SPEC-0149). Requirement Origin: Safety, Engineering M1 Wash Platform Functional Requirements & Specifications Seismic Safety The M1 Wash Platform shall ensure that the M1 Mirror survives the seismic conditions of this specification (basement classification as specified in SPEC-0149) without damage by providing passive restraint of the M1 C&C Support. Verification: Design Review, Analysis Requirement Origin: Safety Mobility The M1 Wash Platform shall be capable of being disassembled and transported between facilities at the observatory site and storage facilities located off-site inside a standard size transport container suitable for truck transportation. Verification: Design Review & Analysis, Safety Personnel Access All areas of the M1 Mirror optical surface and M1 Mirror edges shall be accessible for cleaning. Cleaning shall be possible by hand without the use of tool extensions. This will require access platform(s) to allow a minimum of 2 persons to have close contact with all areas of the mirror optical surface as well as a minimum of 4 persons to have close contact with the edge of the mirror simultaneously at any operational angle. The structure shall also allow free access to the rear surface of the mirror for cleaning and inspection of the mirror and the M1 C&C Support., Safety SPEC-0074 Rev A Page 6 of 12

10 M1 Tilt Capacity The M1 Wash Platform shall be capable of tilting the M1 Mirror during cleaning to drain the optical surface of effluent by tilting of 20 degrees from a horizontal position. Verification: Design Review & Factory Test Effluent Capture The M1 Wash Platform shall be capable of capturing washing effluent and directing it into a containment system provided as a part of the Wash Platform. The containment system shall include pumping capacity to move the effluent from the containment system into AURA supplied containers. The design shall also protect effluent from contaminating the bottom surface of the M1 Mirror or any other surface such as the M1 C&C Support that will be used within the vacuum coating chamber M1 Wash Platform Performance Requirements & Specifications Tilt Adjustment The tilt adjustment of the M1 Mirror on the M1 Wash Platform shall be adjustable with the M1 Mirror and M1 C&C Support on the M1 Wash Platform. The tilt position shall be mechanically locked in place at the two ends of travel (horizontal and 20 degree tilt) Personnel Access Platforms Close proximity of mechanical equipment to the M1 Mirror can cause equipment damage hazards and personnel injury hazards. All movable equipment with the potential for possible mechanical interference shall be clearly identified and mitigated in the required Hazard Analysis. Where possible, interlocks shall be used to prevent hazards. Requirement Origin: Safety 3.2 M1 C&C SUPPORT REQUIREMENTS & SPECIFICATIONS Overview Scope The M1 C&C Support provides a 9-point whiffle-tree type support for the M1 Mirror for use on the M1 Wash Platform, M1 Transport Container and Coating Chamber. The M1 Mirror shall be transferred from the M1 Wash Platform to Coating Chamber using the M1 C&C Support in combination with the M1 Lifter. SPEC-0074 Rev A Page 7 of 12

11 Verification: Design Review Basic Requirements The M1 C&C Support provides lateral restraints for M1 safety in the event of earthquake. The M1 C&C Support shall interface to the M1 Transport Container to safely convey the M1 Mirror between the DKIST and AEOS Coating facilities. The M1 C&C Support shall also interface to the M1 Lifter using guide pins to safely install the M1 Mirror on the M1 C&C Support. The M1 Lifter will be used to transport both the M1 C&C Support and M1 Mirror from the Wash Cart to the Coating Chamber. Requirement Origin: Safety, Engineering M1 C&C Support Functional Requirements & Specifications Seismic Safety The M1 C&C Support shall ensure that the M1 Mirror survives the seismic conditions of this specification (basement classification as specified in SPEC-0149) without damage by providing passive restraint of the M1 Mirror. Verification: Design Review & Analysis Vacuum Compatibility Materials and design of the M1 C&C Support shall be compatible with the vacuum cleanliness levels required for the thermal evaporation coating process. The M1 C&C Support shall be fabricated from vacuum compatible passivated stainless steel. All other materials and surface treatments shall be approved by AURA for this requirement. All surfaces shall be easily cleaned and all trapped volumes within the M1 C&C Support shall be vented to avoid virtual leaks M1 C&C Support Performance Requirements & Specifications M1 Mirror Stress The M1 C&C Support shall not induce greater than 5.0MPa stress levels within the M1 Mirror at any tilt angle or combination of operational, transport and/or survival conditions. Verification: Design Review & Analysis Requirement Origin: Safety SPEC-0074 Rev A Page 8 of 12

12 4. GENERAL REQUIREMENTS AND SPECIFICATIONS 4.1 DESIGN AND ANALYSIS REQUIREMENTS & SPECIFICATIONS To the extent possible, subsystems that are off the shelf or previously designed, built, and tested by Contractor or by AURA should be used to minimize cost and to optimize the ability to maintain and procure spare parts. Design of components should be achieved using the most efficient and effective manufacturing processes to simplify all components and ensure the lowest cost and highest reliability without sacrificing performance. Wherever possible, the M1 Coating and Cleaning Equipment subsystems shall be organized into modules for ease of mounting/dismounting and servicing. Written instructions for the removal, installation, servicing, alignment, and adjustment shall be provided by Contractor for all subsystems. Contractor shall supply all mechanical and electronic hardware associated with each mechanical system, and shall provide all necessary amplifiers, wiring, utility routing, hangers, cable trays, and connections to the appropriate control system to operate the systems. Design of all utility routing shall be subject to approval by AURA. Unless stated otherwise, all requirements and specifications stated in this General Requirements & Specifications shall be subject to verification via design review and inspection Drawings & Documents Requirements & Specifications All detail design drawings shall conform to AMSE Y14.5M All detail design drawings shall be in System International (metric) units with Imperial (inch) secondary units shown in parentheses. All analyses shall be performed in the System International system (metric). All detail design drawings shall be generated in (or transferable to) the latest commerciallyavailable version of SolidWorks. These drawings in PDF format, along with printed hard copies, shall be provided to AURA upon completion of the Work. All computer aided design (CAD) 3D solid models of the M1 Coating and Cleaning Equipment shall be provided to AURA in the latest commercially-available version of SolidWorks format or equivalent upon completion of the Work. Four sets of manuals shall be prepared, containing all information related to maintenance and operation of the pertinent M1 Coating and Cleaning Equipment, so that the information in the Manuals will be adequate to enable DKIST project personnel to perform the full range of expected operating and regular maintenance functions related to the M1 Coating and Cleaning Equipment without the need to seek information from a source other than the manuals. The manuals shall have the maintenance and operating information organized into suitable sets of manageable size, which shall be bound into individual binders properly identified on both the SPEC-0074 Rev A Page 9 of 12

13 front and spine of each binder, which is indexed (thumb-tabbed) and includes pocket folders for folded sheet information. It is anticipated that the Manuals shall also be supplied in electronic form. Such information shall include, but not limited to, all information related to normal operations and procedures, emergency operations and procedures, normal maintenance and procedures, emergency maintenance and procedures, spare parts, warranties, wiring diagrams, inspection procedures, performance curves, shop drawings, product data, and similar applicable information Structural Design Requirements & Specifications Stresses in all members shall be maintained with safe working values for all possible combinations of fabrication, assembly, operation, and seismic conditions. Unless specified otherwise by AURA, a minimum Factor of Safety of 3.0 under any combination of operational and environmental loading shall be used during the course of the Work. Gravity loads, temperature effects, wind effects, and seismic loads shall be combined per an approved standard when determining the critical cases for maximum stresses and deflections Electrical Design Requirements & Specifications All electronic/electrical equipment must have over-current protection (thermal breakers, fuses, lightening arresters, ground-fault interrupts, surge protection, etc.). Fuses must be easily accessible for replacement. All electronic/electrical equipment must have a main line circuit breaker or power switch, and a controlled light indicator for power status. All electrical/electronic installations must comply with National Electrical Code where applicable. All electronic/electrical equipment must have safety grounds. All power and signal cables and leads shall be shielded. Contractor shall define and provide electrical connectors, cabling, and tubing consistent with high reliability operation and EMC constraints. Connectors shall be capable of being rapidly disconnected for service of all assemblies of the UGOS shall be keyed so that incorrect connection is not possible. Proper and appropriate strain relief shall be provided to ensure reliability and to minimize effect of cabling loads. Only high-quality rough-service connectors may be used. Power and signal cables should be shielded for low and high frequency interference. Whenever possible, power and signal wires must be routed separately. The cabling design must avoid ground loops. Cables and tubing shall be capable of withstanding multiple reverse bends. The jacketing material must be resistant to chemicals and abrasion, and remain flexible at low temperatures. The jacket material should be molded onto the conductors, eliminating any possibility of the conductors shifting inside the cable. SPEC-0074 Rev A Page 10 of 12

14 All utilities shall be strain relieved at all disconnects and end points. Shielded cables and armored fiber optic cables must also meet the above requirements. Cables designated for power must also meet the specifications for voltage and amperage capacities as per the U.S. National Electric Code Maintenance Requirements & Specifications The M1 Coating and Cleaning Equipment shall be configured such that all necessary maintenance operations can be easily carried out without risk to personnel or to the equipment. The M1 Coating and Cleaning Equipment shall be configured such that all maintenance requirements are minimal. All maintenance procedures shall be approved by AURA. 4.2 FABRICATION REQUIREMENTS & SPECIFICATIONS Materials and Workmanship Requirements & Specifications All materials used in the Work shall be new and of high grade commercial quality. They shall be sound and free from defects, both internal and external, such as cracks, laminations, inclusions, blow holes or porosity. Workmanship shall be of a high grade of commercial practice and adequate to achieve the accuracies and surface finishes called for on all drawings and in the specifications. All manufacturing processes, such as plating, welding or heat treatment, shall be specified and performed in such a manner as to achieve the strength and properties required without introducing any material defects such as hydrogen embrittlement, excessive grain growth, or residual stress concentrations. All metal edges shall be free of burrs and sharp corners. No sharp edges that might constitute a hazard to personnel or equipment (e.g., cabling) shall remain on the finished components. Materials used by Contractor shall be consistent with all requirements including life cycle, reliability, and maintainability. Substitution (e.g., to obtain improved performance or reduced cost) is subject to written approval by AURA Stress Relieving Requirements & Specifications All welds shall be stress relieved after welding and/or prior to final machining. Shop drawings shall include heat treatment specifications for all parts requiring treatment to meet the performance and functional specifications required of the M1 Coating and Cleaning Equipment. All welded parts, unless specified or approved otherwise by AURA, shall be fully stress relieved prior to final machining operations. SPEC-0074 Rev A Page 11 of 12

15 4.2.3 Surface Finish, Coatings, and Paint Requirements & Specifications All parts of the M1 Coating and Cleaning Equipment shall be finished so as to promote cleanliness of the equipment and to avoid contamination of any mirror surface or instrument. It is of prime importance that all protective coatings are of high quality and long life due to the high cost of recoating and the resulting interference with telescope operation. AURA reserves the right to inspect all surface preparation for each individual coating prior to application. All exposed machined surfaces, unless specified otherwise, shall have a surface finish of 64- microinches or better. Except where otherwise required by specification, all coated (i.e. paint, powder coat, etc ) external surfaces of any equipment that is a part of this specification shall be yellow in color according to the standard color code RAL All finishes shall be durable against atmospheric and sun exposure, airborne dust impact, personnel access on and around the structure, and any other expected wear conditions including chemical exposure defined within this specification. 4.3 PACKING AND SHIPPING REQUIREMENTS & SPECIFICATIONS Contractor shall be responsible for all aspects of shipping, including shipping arrangements, shipping, handling, and storage costs, transportation permits, customs and port of entry fees, taxes, and all other costs associated with transporting the M1 Coating and Cleaning Equipment components from the Contractor s facility to the Site. All materials and equipment for shipment shall be prepared in such a manner as to protect them from damage in transit and storage. Special care shall be taken with electrical and electronic components, which shall be packed with a dehumidifying agent to effectively deal with condensation. Proper identification of parts and adequate provision for slinging and handling of equipment without damage shall be made. All packaging, packing materials, slinging, and handling equipment design shall be approved by AURA. SPEC-0074 Rev A Page 12 of 12