Pyrometry

Bob Faticanti

Sr. Manager Supplier Development Eng. /

Textron Defense Systems

Chemical Processing

October 21, 2012

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

IMPROVE UNDERSTANDING OF PYROMETRY BASICS

Objective #1

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

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?

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

AMS 2750 Rev D

AMS 2750 Rev D

Let’s Start with

Thermocouples,

Controllers and Recording

Instrumentation

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.

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

Other items on Site

• Check if the Supplier has the items

required to be on site per 3.5.21.2

Tested within oper. range

System Accuracy Testing

System Accuracy Test – tests the accuracy of the control T/C

What does the SAT need?

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

Temperature Uniformity Survey

Temperature Uniformity Survey tests the variation in temperature within a defined space.

Example TUS rack:

WORK ZONE

AMS 2750 Rev D

390 Cubic Ft. Furnace

What Does TUS Report need?

Accepted and signed by QC.

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

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.

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

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?

IMPROVE UNDERSTANDING OF AC7108 SECTIONS 5.4 AND 5.5

Objective #2

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?

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.

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.

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?

Questions