CP Training on Pyrometrics
description
Transcript of CP Training on Pyrometrics
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Pyrometry
Bob Faticanti
Sr. Manager Supplier Development Eng. /
Textron Defense Systems
Chemical Processing
October 21, 2012
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Objectives of Training
1. Improve Understanding of Pyrometry
Basics
2. Improve Understanding of AC7108
sections 5.4 and 5.5
3. Communicate AMS 2750 Rev. E
4. Answer any questions
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IMPROVE UNDERSTANDING OF PYROMETRY BASICS
Objective #1
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AC7108 section 5.4 • Only required to verify the questions in this
section.
• However, AMS 2750 is considered the
baseline requirement
• Customers may have higher requirements
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High Level
• Does it look like they know what they are doing?
• Check the procedure, SAT and TUS reports
• Considerations – Does the Supplier also do Heat Treating?
• Are they Nadcap accredited for Heat Treating?
• Are their HT pyrometry systems also over the CP Thermal Processes?
– Does the Supplier do the pyrometry themselves?
– Does the Supplier outsource pyrometry?
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Procedures
– Even if Outsourced • Replacement of control sensors (typically annually per 3.4.3.4)
• SAT procedure
– Frequency
– Correction factors
• TUS procedure
– Define Work Zone → Size affects # of sensors and locations → Corners of TUS
sensors = Boundary of where product can be placed → Needs communicated to
shop
– Survey temperatures and qualified operating range
• Quality needs to review
– Any maintenance that could affect SAT
– Any furnace modifications (defined 3.5.3) that could affect TUS
– Address any out of tolerance needs evaluated per material review procedures
• Quality needs to review and approve Instrument Calibration, SAT Report, and
TUS Reports
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AMS 2750 Rev D
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AMS 2750 Rev D
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Let’s Start with
Thermocouples,
Controllers and Recording
Instrumentation
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Thermocouples (T/C)
• Sensors have errors. This needs accounted for or the SAT/TUS data is wrong
• Does the Certificate of Compliance for the T/C State the Correction Factor or Deviation? – NOTE: They need to reverse the sign if it lists a “Deviation”
• Average Front to Back of the wire at a given temperature
• Always add the Correction Factor algebraically – e.g. on the following example. If the Temperature measured shows 1510F
then the true value is 1510 + (-1.5) = 1508.5F.
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T/C Correction Factor Cont.
• Was the T/C Correction Factor Determined
correctly?
– Do Not Extrapolate Beyond Calibration Range
– One can use various methods but be consistent
• Use the closest value
• Use correction factor that is the highest
• Use the correction factor that is the lowest
• Linearly Interpolate between Temperatures
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Other items on Site
• Check if the Supplier has the items
required to be on site per 3.5.21.2
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Tested within oper. range
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System Accuracy Testing
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System Accuracy Test – tests the accuracy of the control T/C
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What does the SAT need?
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Weekly System Accuracy Test (S.A.T.) Results
Week: 3/11-3/17 Year: 2012
Test Instrument Test Sensor
Identification/Information Controller Test
Sensor Disposition
Furnace Initials Date Time Handheld ID# S/N
Due Date for
Handheld Calibration
E Handheld Correction
Factor
Type (Probe or T/C) S/N or ID
Calibration Cert./Spool
#
D Correction
Factor
Due Date for Probe
Calibration Temp.
Setpoint Offset
A Temp Actual
B Temp As
Read
C (B+D+E) Temp.
Corrected
F SAT
Difference (C-A)
Accept / Reject
Quality Initials
A Z1 VD 3/14/12 4:17 AM 09-170 5/9/12 -1 P 15222 15222 0.65 5/13/2012 980 0 980 976.6 976.25 -3.75
A Z2 VD 3/14/12 4:17 AM 09-170 5/9/12 -1 P 15219 15219 0.35 5/13/2012 980 0 980 977.1 976.45 -3.55
B Sol VD 3/13/12 2:34 PM 09-170 5/9/12 -1 P 15226 15226 1.08 5/6/2012 1000 0 1000 998.1 998.18 -1.82
C Sol VD 3/15/12 12:36 PM 09-170 5/9/12 -1 P 15176 15176 2.5 4/30/2012 1000 0 1000 1000.1 1001.6 1.6
D Sol 09-170 P 0 0
E Sol VD 3/14/12 11:04 AM 09-170 5/9/12 -1 P 15233 15233 1.25 4/28/2012 980 0 980 975.6 975.85 -4.15
0 0
A age VD 3/14/12 8:19 AM 09-170 5/9/12 -0.8 P 15227 15227 0.2 4/30/2012 370 5 365 365.6 365 0
B age VD 3/15/12 11:00 AM 09-170 5/9/12 -0.9 P 15218 15218 -0.1 4/30/2012 475 -5 480 474.4 473.4 -6.6
C age DOWN 09-170 P 0 0
D age VD 3/15/12 4:30 AM 09-170 5/9/12 -0.8 P 15210 15210 2.01 4/17/2012 370 -5 375 373 374.21 -0.79
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Temperature Uniformity Survey
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Temperature Uniformity Survey tests the variation in temperature within a defined space.
Example TUS rack:
WORK ZONE
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AMS 2750 Rev D
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390 Cubic Ft. Furnace
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What Does TUS Report need?
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Accepted and signed by QC.
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TUS Checklist
• Does the TUS show high & low T/C results
• Did the TUS run for 30 minutes after all T/C’s are stabilized? Does it show data before they are stabilized?
• Was the correct number of T/C’s used? (see table 11 for required #)
• Is there a diagram of the locations? (see 3.5.13.2 for required locations)
• Did they use a rack? If so is the load condition maintained per 3.5.10
• What is the operating range of the oven/furnace? Are the high and low surveyed at least once per year?
• Each Oven/Furnace must be identified with the operating Temperature Range: ex. 350 – 1000 F
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Passing SAT/TUS • Checklist requires Class 5 unless more stringent
is specified by the customer.
• Specified by customer by detailing a temperature range, e.g. 550 +/- 15 makes it class 3. See 3.3.1 Figure A.
• SAT – To pass = +/-5 F unless more stringent class is
specified by the customer
• TUS – To pass = +/-25F from set point unless more stringent
is specified by customer.
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AMS 2750 D Para 3.3.1
Figure A • Furnace Class - Temperature Uniformity Range (Degrees F) - Temperature Uniformity Range (Degrees C)
1 +/- 5 F +/-3 C
2 +/- 10 F +/-6 C
3 +/- 15 F +/-8 C
4 +/- 20 F +/- 10 C
5 +/- 25 F +/- 14 C
6 +/- 50 F +/- 28 C
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Failing a TUS/SAT
• Did the TUS/SAT report state fail?
• Did any fail but not state fail?
• Did the Supplier take action? e.g. MRB for
all product since last good test
• If the external report stated failed was the
supplier notified by the pyrometry vendor?
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IMPROVE UNDERSTANDING OF AC7108 SECTIONS 5.4 AND 5.5
Objective #2
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5.5 Misc. equipment below 250F or
otherwise not controlled by 5.4 • The key point is to avoid overheating parts which could be damaging or to
ensure any customer requirements are met.
• 5.5.1 – Are there controllers? Are they calibrated? Check records, check
calibration recall system, check sticker on the controllers
• 5.5.2 – This is basically asking for a TUS light. They may not be following all of
pyrometry rules but need to define the space for the product and testing sensors. Are there procedures? Is a frequency defined? Are max temperatures checked? Are min temps checked if applicable? Is the work zone defined? Is it defined how test is done?
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TBD
• Once AC7108 Rev F is finalized, it needs
to be reviewed to determine what, if any
changes need to be emphasized to CP
auditors.
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AMS 2750 Rev E • AMS 2750D went into effect in 2005
– Substantial overhaul of Rev. C
• Rev E went into effect – July, 2012 ~50 editorial changes or changes to clarify rather than alter the technical requirements.
~25 changes noted as changes to technical requirements
• Provide a handout summarizing changes. – Highlight those applicable to CP.
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TBD • Now that AMS 2750 Rev E is finalized, it
needs to be reviewed to determine what, if
any changes need to be communicated to
CP auditors to look for.
• Examples: Are Suppliers aware revision
has changed? Do they have a copy of it?
Are TUS/SAT reports from a vendor to the
latest revision?
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Questions