SECTION 000000 - Chrysler · Web view2-way solenoid valve with Viton seals Coax MK##2C2##VPB###T20XB 18 2-way externally controlled Coax VMK##2C2###CTB###XX2VBXXP1 with flow controls

Chrysler Construction StandardsAME-PT Plants

11/20/2008

SECTION 15193 – HIGH PRESSURE COOLANT PUMP SKID

PART 1 - GENERAL1.1 DEFINITIONS1.2 SUBMITTALS1.3 DELIVERY

PART 2 - DESIGN AND PRODUCTION2.1 MACHINE TOOL SIGN-OFF2.2 HIGH PRESSURE COOLANT PUMP SKID REQUIREMENTS 2.3 ELECTRICAL CONTROLS2.4 TAGGING2.5 PAINTING 2.6 SOUND LEVEL/NOISE ABATEMENT2.7 ASSEMBLY and RUNOFF

PART 3 - DOCUMENTATON3.1 DRAWINGS3.2 OPERATION AND MAINTENANCE MANUALS3.3 SPARE PART LIST 3.4 PFMEA

PART 4 - SUPPORT4.1 INSTALLATION SUPERVISION / SERVICE4.2 COORDINATION4.3 TRAINING4.4 PAYMENT TERMS and CONDITIONS

HIGH PRESSURE COOLANT PUMP SKID VENDOR MUST RECEIVE AND INCLUDE THE DATA SHEET FROM THE MACHINE TOOL SUPPLIER FOUND IMBEDED TOP OF PAGE 3 SECTION 2.1. HOLD CTRL. KEY AND LEFT DOUBLE CLICK.

PART 5 - Related Sections include the following from

http://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain.htmlSection 15050 “Basic Mechanical Materials and Methods”Section 15110 “Division 15 Section Valves”Section 15122 “Meters and Gages”SMI-148 “Maintenance of Water Based Coolant”Section 15185 “Cutting Machine Coolant Piping”Section 15980 “Total Maintenance Spare Parts”Section 15950 “Testing Adjusting and Balancing”Section 15970 “Machine Tool & Process Equipment Installations”Section 15980 “Total Maintenance Spare Parts”Powertrain Operation Machine Tool Specifications Design RequirementsETI-103, SMI-105

Total Maintenance System

HIGH PRESSURE COOLANT PUMP SKID SPECIFICATION 15193: 1 of 21

T3588MP, 11/19/08,

Shown Twice

http://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain.htm


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PART 1 - GENERAL

1.1 DEFINITIONS

Gage: Device or machine designed and intended to check part features or a device to measure temperature or pressure of fluids or gases.

Fitting: Fitting installed on, or attached to, utilities connecting to equipment which allows for equipment removal or modification.

1.2 SUBMITTALS

A. Drawings & Manuals: Within four (4) weeks of receiving a purchase order, the OEM shall submit one (1) hard copy and one (1) electronic set of prints to AME-PT engineer for Chrysler‘s approval. With shipment, the OEM shall supply and ship one (1) set of paper copy drawings with machine and one CD of drawings and operation and maintenance manuals to the responsible AMEPT engineer. Once installed and qualified, the OEM shall update and ship three (3) paper sets of operation and maintenance manuals showing component parts such as pumps, fans, motors, automatic valves, bearings, etc. to the plant representative as directed by the responsible AME-PT engineer. A signed copy of the Letter of Transmittal and a CD containing all “as installed” drawings of the equipment, operational maintenance manuals, and scanned electronic copy of all individual component specification (“cut”) sheets and all spare parts lists to the responsible AMEPT Engineer.

B. Chrysler will supply the brass tag and drawing numbering system when the purchase order is issued. Supplier must conduct a Cad Administrative Agreement following the placement of the purchase order.

C. All floor plan drawings must show the complete plan view of the entire machine as it sets on the floor. Its base, including projections for leveling or anchoring, shall be shown in heavy dashed lines. Heavy solid lines shall be used for any and all projections above the base including tanks, housing, platforms, conveyors, load and unload locations, panels or any other part of the machine. Clearance for service, including panel and access doors (open position) shall be shown in the proper location. Show all locations of piping, drains, exhaust stacks, and air intakes. Ancillary equipment such as electrical panels and filters shall be shown in correct relation to machine and dimensioned. In no case shall the equipment be located so as to prevent ease of access for service or repairs of any component of the machine or ancillary equipment.

D. The scale floor plan drawings shall be updated each time a revision is made and submitted for approval to Chrysler prior to altering the machine, ancillary equipment or orientation.

E. All engineering drawings shall be developed using the CAD software and version agreed upon in CAA.(CAA shall be used in reference to “cad administration agreement”). All engineering drawings, upon successful completion of this project become the property of Chrysler Corporation.

F. Maintenance Manuals in English shall also be developed in an electronic format utilizing Microsoft Word or Adobe Acrobat. All graphics must be embedded into the document, not linked.

G. The OEM shall provide a recommended spare parts list for all of the supplied machines. Included in this list shall be a “where-used” list, current cost of parts, and lead-time in weeks. The spare parts list shall be per Chrysler TMS electronic format refer to “Total Maintenance System” (refer to web site https://gsp.extra.chrysler.com/mfg/amedd/powertrain.htm).


https://gsp.extra.daimlerchrysler.com/mfg/amedd/powertrain.htm


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H. Field Utility routing to equipment and gages including planned placement of all cranes, pull boxes, disconnects, control panels, isolation valves, (including lockout valves), supports, flow balancing valves, flow meters, gages and anchors and sway bracing. Do not route utilities in the path of the automation such as gantries or in the path of any cranes.

I. Wiring diagrams in controls submittals for all field-installed wiring showing panel terminated insulation labels and color of wire

J. All installation submittals must show code clearances such as 42 inches from front of a panel to any obstruction and 48 inches from the fronts of two opposed facing panels.

K. All means of egress between equipment must have a minimum of 28 inches.

1.3 DELIVERY

A.The skid supplier shall be responsible for shipping their system to the machine OEM for runoff with the machining equipment. This includes any and all overseas shipments to and from OEM with F.O.B. Chrysler plant.

B. Delivery of all equipment shall be coordinated through the Chrysler designed field representative. No deliveries shall be made without their directions.

C. Each item will have the following information visible on its exterior upon delivery: Chrysler’s purchase order number, Chrysler brass tag number, Attention: (Name, Title, Facility, Address, Phone #), equipment description and bay location.

D. All equipment shipments shall include equipment installation drawings.

E. All equipment shall be packed and/or palletized to insure ease of installation. All shipments shall be made in covered truck. The High Pressure Skid tank and the Back-Flush Filter must be drained prior to shipment.

F. At the Chrysler facility a designated contractor prior to unloading shall inspect all equipment. All damage shall be reported on the shipper, and to the appropriate Chrysler plant engineer

Part 2-DESIGN AND PRODUCTION

2.1 MACHINE TOOL SIGN-OFF (HIGH PRESSURE PUMP SKID DATA SHEET)

2.2 HIGH PRESSURE COOLANT PUMP SKID REQUIREMENTS

A. Design shall allow for ease of maintenance and sound control, at or below Chrysler sound limits individually as well as an integrated system with multiple noise sources. (refer to application and anticipate compounding of sound generating equipment)

B. System shall be and maintain dry floor design, NO LEAKS!

C. The coolant tank shall include a “clean-out” door for easy tank cleaning. Minimum size of this door should be 7 inches high by 36 inches wide, so as to allow access inside of the tank. In addition, the bottom of the cleanout door shall be fully flush with the inside bottom of the tank, with no lip between the inside tank bottom and the cleanout door. Please see appendix 2 for illustrations and details.


https://gsp.extra.daimlerchrysler.com/mfg/amedd/aamebldg/pto_mods/HP%20SKID%20RFQ_REV.7-31.xls

https://gsp.extra.daimlerchrysler.com/mfg/amedd/aamebldg/pto_mods/HP%20SKID%20signoff_REV.7-31.xls


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D. Clean out doors must have hand operated fasteners for “limited tool” access. No round “hydraulic tank style” doors allowed.

E. Clean out door seal shall be one piece full door construction.

F. Tank level sight gage should be cleanable without draining the tank i.e. with isolation valves and tee fittings.

G. Tank shall be constructed of steel and be of sufficient strength to avoid oil canning. The tank top requires a non-ferrous, galvanic compatible material to minimize rust and corrosion.

H. The tank shall be provided with an Anti-Cavitation assembly to prevent entrained air and vortexes from entering the pump suction.

I. Tank shall have an overflow “weir” at one end, with a visual access door at the top.

J. The visual access door shall be designed to prevent the introduction of foreign debris to the coolant water.

K. Tank shall include a minimum adjustable set point fill device to eliminate stagnation during shutdown periods (refer to components list).

L. Tank shall include a high limit fluid temperature switch to signal a cycle stop to the machining equipment and then shut down the high pressure pump (allow complete cycle stop before shutting down pump) then alarm if the fluid temperature approaches the maximum recommended by the pump manufacturer.

M. Tank shall be baffled for proper coolant flow and eliminate cavitation at the pump suction.

N. The tank shall be elevated, so as to allow a gravity drain at the bottom of the tank. The drain lines shall be sized to completely drain the tank at a rate of 6 to 10 minutes per 300 gallons.

O. Inside tank bottoms shall be sloped towards both the clean out door, (for easy removal of debris), and the tank drain, (to ensure complete tank drainage). Please see attached drawings for details and clarification.

P. Coolant pump suction valve shall include electrical position monitoring. Valve must be in open position to allow pump operation.

Q. All drip pans to be pitched a minimum of 1/8” per foot and include a drain valve and minimum 1 inch drain line.

R. A separate PLC system for the skid shall monitor and control all functions independent of the machines except for interlocks from the machines, which shall start and stop pumps. All PLC, panel and components shall meet Chrysler Control Specifications.

S. Fluid level controls to indicate “full”, “shut down warning”, and “empty” levels. In addition, auxiliary output signals shall be provided to cycle stop the machining process upon a “shut down warning” level indication. Tank size must allow for continuous high pressure flow during the time the “shut down warning” level is reached, and the machine can be automatically cycle stopped, assuming loss of fluid supply to the tank.

T. System shall include fluid monitoring for outlet pressure differential pressures and set points adjustment across the filter media.



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U. System shall include coolant outlet pressure adjustment with pressure relief back to the clean tank.

Where multiple pumps are used on one skid, each pump shall have lockable suction and discharge valves to allow independent pump maintenance. Valves shall have electrical position monitoring. The inlet and outlet valves must be open to allow the pump to start or run.

V. System shall include a “Hedland” flow monitor, with a visual indicator for the high pressure pump outlet.

W. All gages and visual indicators shall reflect good “Visual Management” practices including placement of devices and tagging per Chrysler Engineering.

X. Incoming coolant flow shall be modulated for an adjustable, settable minimum overflow. This will use a “Cla -Val” modulating valve with a coolant operated pilot and float switch.

Y. Automatic back flush filters shall be used as sentinel filters to protect the high-pressure pumps and tooling. The automatic backflush filters shall use two dimensional 60 micron absolute . Nominal micron ratings will not be considered.

Z. The media cylinder shall consist of a stainless steel or nickel micro screen with underlying rolled perforated stainless steel plate. The element with media must withstand a differential pressure of 100 psig. in either direction without failure or implosion.

AA. Media shall provide a flux rate of 25-35gpm per square foot. Higher flux rates will be subject only by the approval of AME and justifiable by the design of the filter.

BB. The filter element shall be automatically cleaned with a compressed air backflush. The compressed air shall be supplied with its own approved t-handle lockout device and regulator. The compressed air shall have a sufficiently sized receiver tank to properly operate the valves and back flush sequence. A check valve must exist between the coolant and compressed air interface to prevent coolant from backing up into the pneumatic system. An air pressure switch shall monitor and alarm in the event the compressed air drops below 10 psig at the pneumatic valve manifold.

CC. The filter element backflush sequence shall be initiated from a timed cycle of no more than every 60 minutes with differential pressure over-ride set to occur at 4 psig with 1 second time delay on the switch sensing so as not to cause rapid sequencing of the filter

DD. The automatic backflush filter shall be furnished with pneumatic flow controls on the incoming and outgoing coolant valve actuator. All controls, valves, actuators, solenoid valves, manifolds, switches etc. to provide a functioning backflush unit shall be provided.

EE. Refer to attached drawing for clarification of skid, filter and piping layouts.

FF. Tank Sizing shall be calculated according to the “attached “RFQ – “Machine Tool Signoff High Pressure Pump Skid Data Sheet” for OEM requirements and check lists.

GG. The backflush controller shall be labeled inside the panel describing the functional key activation and normal set points.

HH. All unit functions, including pressure and flow, will be tested and run-off for acceptance on the suppliers floor.



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II. Supplier quotations must include a proposal drawing and a specific description of how the runoff specifications will be met.

JJ. Skid supplier is responsible for delivering a system that is “robust and capable” as determined by plant and AME Powertrain engineering/management.

KK. Supplier is required to submit an installation and foundation drawing.

2.3 ELECTRICAL CONTROLS

A. All electrical systems shall conform to the latest Chrysler Powertrain Control Specifications detailed on the Chrysler AME web site.

B. Each individual motor in the system shall have its own fused safety disconnect that shall be mounted and wired in close proximity to the motor it serves but not in the way of service.

C. All motors used shall be T.E.F.C.B.B. “U” frame premium efficiency; (T-frame high efficiency may be acceptable with technical & cost justification). Refer to AMEPT Controls Specifications

D. All motors shall be 1,750RPM or 3600RM unless specifically designated and/or otherwise approved in writing.

E. All separation points in the system shall terminate in a junction box with terminal strips or Harding connectors for ease of connection.

F. For all wiring refer to Chrysler’s Powertrain Controls Specifications.

G. The successful supplier shall be responsible for including all electrical components or other components, not specifically mentioned or, required to make a fully automatic, safe and Chrysler Engineering approved functioning system. All pneumatic tubing shall be per the AMEPT Controls Specifications.

2.4 TAGGING

A. All wiring, panels, and pneumatics, hydraulics, valves and set points shall be tagged per Chrysler Powertrain Controls Specifications.

B. All gauges shall be identified with normal operating ranges.

2.5 PAINTING

A. All painting will conform to Chrysler Corporation color code and paint standards.

B. The successful supplier shall be responsible for ensuring all parts of this system are painted to conform to Chrysler Standards. This will include all electrical panels, piping, tankage and guarding. Items that are immersed in liquid such as internal tanks are not to be painted. Review questions with Chrysler Engineering.

2.6 SOUND LEVEL/NOISE ABATEMENT



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A. Equipment will be designed to meet the latest Chrysler Standard Sound Requirements as set forth in the Chrysler Safety Specifications.

B. Any enclosures required to ensure that these sound requirements shall be met shall be indicated in the proposal.

2.7 ASSEMBLY and RUNOFF

A. Equipment will be assembled on supplier’s floor, for the purpose of inspection by Chrysler, and run off per the “authorization to ship process”. Chrysler Plant Engineering must approve and sign the ATS prior to shipping.

B. Items to reviewed by supplier prior or during runoff:

Drive guards installed.

Tanks mounted and piped.

All tank welds must be dye penetrate tested.

All tanks must be filled with water and leak tested.

Skid shall be run for a minimum of eight (8) continuous hours with the machine tool equipment.

Level Control/Pneumatic Panels mounted, plumbed and wired on the skid.

High pressure pumps shall be dry mounted and located within the bases drip pan, complete with Suction and Discharge Piping in place, including all interconnecting piping.

All PLC & HMI programs will be loaded on supplier’s floor. Control Panels will be fully functional tested for proper control, monitoring and operation prior to shipment (refer to AMEPT Controls Specifications).

Motor Disconnect switches shall be fully wired to motors and control panel.

C. Each skid will be subject to a minimum two (2) weeks of continuous leak free running, with reasonable loading, on Chrysler’s floor prior to full acceptance by Chrysler.

2.8 Lessons Learned

A. Provide a high temperature limit switch mounted in the tank to shut off the high pressure pump if the coolant temperature reaches 10 degrees F. below the lesser of the two, pump manufacturer or Coax valve manufacture recommended high temperature limit.

B. Provide assistance with recommended distribution piping layouts servicing the machine tools.

PART 3-PFMEA



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3.1 PFMEA requirement shall be completed per Chrysler standards.

PART 4-SUPPORT

4.1 INSTALLATION SUPERVISION / SERVICE

A. Supplier shall provide in the quotation adequate service time to support the installation at the Machine tool OEM location and Chrysler facility for debug and system integration.

B. A minimum of (2) days at the machine tool supplier per skid system used for runoff, and five (5) days of service for installation and start-up supervision at Chrysler’s plant per skid system shall be included in the quotation. No additional funding will be provided for hours, living or travel expenses once the P.O. is awarded.

C. Service should be quoted based upon ten (10) hours per day, Monday through Friday only.

D. As a part of the quotation, supplier will also state per diem and hourly rates, including travel and living for straight time, overtime and holidays. NOTE: Additional funding will not be made for a non functioning skid due to incomplete or uncoordinated startups.

E. The vendor supplied supervision will be on call, and available to the plant, within twelve (12) hours of the call, at any time deemed necessary by Chrysler.

F. Chrysler Corporation or designated Union trades shall install equipment per the supplier’s recommendations.

4.2 COORDINATION

A. The successful supplier of the skid shall attend coordination meetings with the machine tool equipment supplier. These meetings will be scheduled at a minimum once per month, beginning once the contract is awarded to the skid supplier, until the design is complete.

4.3 TRAINING

A. Three (3) days of On-Site Training Services for each type of skid system must be separately included in the quotation.

B. Training shall be quoted based upon three (3) days, 8 hours per day Classroom and Field Training at Chrysler facility for ten (10) personnel.

C. Training will include both electrical and mechanical aspects of the skid systems.

D. Pricing will include a total of ten (10) training manuals per plant.

E. The cost for training shall be submitted as straight time and can include travel and lodging

4.4 PAYMENT TERMS and CONDITIONS



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A. Partial payment shall be made as equipment is built and stored or shipped to Chrysler facility, or supplier. Final 10% payment shall be made when Chrysler engineering has all as-built drawings, electrical and fluid power drawings, operation manuals, instruction manuals, as installed/qualified final software, and spare parts lists. Also required for final payment will be delivery and approval of any other components required for the system, covered in this specification or others. Refer to purchase order for further detail.



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1.1 Appendix 1: Approved Components

Components not listed will be considered only if a written deviation is submitted to the Chrysler Plant Engineer by the OEM. Chrysler PT Plant or Controls Engineers will determine acceptability. If the deviated components are not considered acceptable, the Chrysler specified components shall be used at no penalty or liability to Chrysler.

MANUFACTURER DISTRIBUTOR CONTACT-DETAILS

1.1.1 Coolant Reservoir – Miscellaneous1 Source for high pressure coolant system Mann-Hummel

RHMRock/Tool&Machine

Mann-Hummel, Mark Donatiello (248)-467-8410Emil Muccino (734)326-5400Clayton Kessler(734)455-9840

2 10 micron breather for high pressure system SchroederHydac

MBF-10MP20BLP

3 Min ¾” dia. Sight Gauge – Must be cleanable without draining reservoir

RHMMann-HummelRock/Tool&Machine

Emil Muccino (734)326-5400 Mann-Hummel, Mark Donatiello (248)-957-8410Clayton Kessler(734)455-9840

4 Level Controller & low level switches Cla-Valve Liquid Piloted

5 Level control valve Cal-Valve Mechanical Float modified w/ minimum set point bolt and locking nut

1.1.2 Coolant Pumps and Accessories6 High pressure pump

Knoll

Brinkmann

Andy Hatch (248)-320-9805

Stefan Hellweg (248)-926-9400

7 Low / medium pressure pump Brinkman Stefan Hellweg (248)-926-9400

8 4-bolt flange for high pressure system AnchorVictaulic

Standard series

9 Flange bell housing to couple pump/ motor VescorBSF

XXXXXX

10 Flow meter Hedland H series

1.1.3 Coolant Couplings and Clamps11 Coupler (headers) Victaulic Style 770M groove style

12 Heavy duty clamp Hydac Parker

Standard series88-HC-H

13 Quick disconnect couplings for auxiliary header ISO1179

CejnHansen

10 414 Series Nipple, 414 Series CouplingHK series

1.1.4 Coolant Filters14 60 micron self cleaning and backflushing filter Snow Technologies Inc

Boll Filters ,Rosedale, Zealtek

Contact Chrysler for phone #Kurt Borseth (734)-451-4681Rich Fogel (248)347-4800



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1.1.5 Coolant Valves15 2-way manual ball valve - high pressure Coax

HydacXXXXKHB or KHM series

16 2-way manual ball valve - low pressure 2 Apollo 3 Apollo Parker

4 83-10#-01-P01 (1/4” – ½”) 5 83-10#-01A-P01 (3/4” – 2”) V-500-P

17 2-way solenoid valve with Viton seals CoaxMK##2C2##VPB###T20XB

18 2-way externally controlled Coax VMK##2C2###CTB###XX2VBXXP1 with flow controls

19 3-way pilot actuator valve HydacCoax

KH2 with BAV*VMK##3C2###VTB####XX2VBXXP1 with flow controls

20 3-way direct acting Coax MK##3C2##VPB###T20XB

21 3-way manual ball valve ParkerHydac

BV3DKH3

22 Check valve for high pressure system HydacSun

RV-*-1.0/12-*-VCX

23 Diverter with pneumatic actuator Hydac Victaulic

KHB3K-* Style 300

24 Flow control valve for high pressure system HydacParker

DRV-12-1.1/12-*-M9 F series

25 Electronic Pressure Sensor IFM-Effector or equivalent

PN1024 (4-20mn)

26 Electronic Pressure Transducer IFM-Effector or equivalent

PA 3224

27 2 way automatic Ball valves direct coupled Ferguson FNW FNW 310M

28 Pneumatic Actuators Bellimo Valbia Double Acting (DA)

29 Pneumatic Valve Manifolds ParkerRexrothNumatics Series 2005



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APPENDIX 2: Skid Assembly Design Example Drawings, 7 Total(AutoCAD example files available from Bill Davis, 248-512-0304, [email protected],)

5.1Drawing #1



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5.2Drawing #2

5.3Drawing #3



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5.4Drawing #4



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5.5Drawing #7



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5.6Typical Pneumatic Circuit Design



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TYPICAL COOLANT SCHEMATIC



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APPENDIX 3: Tank Design Example Drawings, 6 Total(AutoCAD example files available from Bill Davis, 248-512-0304, [email protected],)

5.7Drawing #1

5.8Drawing #2



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Drawing #3

5.9Drawing #4



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APPENDIX 4: Typical Skid Drain Example Drawing, 1 Total(AutoCAD example file available from Bill Davis, 248-512-0304, [email protected],)

5.10 Drawing #1


The above sketch is for reference only. It will be the responsibility of the installing contractor to design the purge discharge into the flume without any splashing, misting or spillage onto the floor.

Documents

SECTION 000000 - Chrysler · Web view2-way solenoid valve with Viton seals Coax MK##2C2##VPB###T20XB 18 2-way externally controlled Coax VMK##2C2###CTB###XX2VBXXP1 with flow controls