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  • Analytical Chemistry & Metallography Glovebox

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Analytical Chemistry & Metallography Glovebox

Project Scope: Engineering / Design Drawings, Seismic Analysis, S/S Fabrication, Kynar® Lining, Final Assembly, Helium Leak Testing, ASME NQA-1. 

The Analytical Chemistry Glovebox and the Metallography Preparation Glovebox (not shown) were Kynar® lined Type 304L stainless steel glovebox assemblies that Springs Fab designed and built for a DOE facility. The engineering phase of the project involved production of preliminary design drawings, preliminary design review, detailed mechanical and electrical design drawings, and structural / seismic calculations. Drawings were revised as needed to produce as-built drawings at the completion of fabrication. Springs Fab fabricated the gloveboxes and their appurtenances, subcontracted the lining, completed the assembly, and performed the helium leak testing.

  • Integrated Glovebox & Advanced CMM

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Integrated Glovebox & Advanced CMM

Project Scope:  Fabrication; Mechanical & Electrical Assembly; Set-up & Commissioning of Dri-Train System; Leak Testing, System Testing (Functional & Atmospheric Parameters); ASME NQA-1.

Springs Fab, working with Merrick & Company as a design/build team, supplied the fabrication, assembly, testing and delivery of an integrated glovebox and atmospheric control system to a DOE facility. The glovebox is used to enclose and stabilize an extremely sensitive Coordinate Measuring Machine (CMM).

The CMM is mounted to a heavy granite table, and its work process is highly sensitive to oxygen, moisture, and temperature.  Work pieces are introduced into the glovebox via a Rapid Transfer Port (RTP) interface.  Viewing is accomplished with large windows, and aided by a high resolution video camera.  All work must be done within a glovebox nitrogen atmosphere at a near zero concentration of oxygen and moisture, maintained by a dri-train gas purification system.  The glovebox is sealed against the granite table.  In addition to the CMM machine, the integrated system includes an internal jib crane, RTP port, a rotary probe change rack, atmospheric monitors (O2 and H2O analyzers), electrical controls and HMI panel, high resolution camera and view portal, gas purifier, and piping.

  • Moore Base Lathe & Staging Gloveboxes

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Moore Base Lathe & Staging Gloveboxes

Project Scope: Springs Fab provided the fabrication, assembly, testing and delivery of the Moore Base Lathe and Staging Gloveboxes to a DOE facility.  The gloveboxes enclose a Moore T-lathe, and provide parts staging, atmospheric control and radiation shielding.

The Moore Base Lathe Glovebox is constructed of 5/8” T304L stainless steel plate.  Springs Fab fabricated this glovebox along with the Staging Glovebox (not shown), and also supplied copper utility piping that has typically been constructed in the field.  The assessment by the customer was that Springs Fab saved the project significant cost and schedule by including the piping in our scope.  In addition to the gloveboxes and piping, the system final assembly included O2 and H2O analyzers, and a hydraulic pump that will supply functional power to the Moore T-lathe in the field.

Specific Activities Performed by Springs Fab:

·         Fabrication of 5/8” plate glovebox, polished to an ASTM A 480 #4 finish (32Ra)

·         Fabrication of lead shielded Parts Staging Glovebox

·         Fabrication of copper piping with valves and plumbing components

·         Assembly of atmospheric analyzers

·         Final leak testing and system FAT testing

·         Disassembly, crating, and shipment

  • Pyrochemical Line

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Pyrochemical Line

Project Scope: Fabrication, Assembly, Testing; Lead Shielded Gloveboxes; Material Transport Tunnel & Material Transport Conveyor; Service Piping; Control System; Complete Integration; ASME NQA-1.

The Pyrochemical Line is an assembly of lead shielded gloveboxes connected to a material transport tunnel that contains a trolley system for automated transfer of materials between gloveboxes. Gloveboxes contain furnaces, presses, and other plutonium processing equipment. Engineering design was performed by an engineering company contracted to a DOE facility, and all construction including fabrication, assembly, and electrical and control systems was performed by Springs Fab. At the time of the pictures the gloveboxes, the tunnel, and the transport trolley were complete. Connecting gate valves between the gloveboxes and tunnels, and the control system assembly and testing remain.

  • Syringe Tub Electron Beam Sterilizer

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Syringe Tub Electron Beam Sterilizer

Project Scope: Engineering / Design from Conceptualization through Completion; Mechanical Engineering / Design; Product Conveyor, Actuated Radiation Shields, Airflow and Ozone Exhaust, Class A Sterile Pharmaceutical Environment; X-ray Radiation Shielding; High Voltage Distribution; Safety Interlocks and Controls; Complete Fabrication and Assembly; Operational Testing and X-ray Shield Cabinet Certification. 

The Syringe Tub Electron Beam Sterilizer irradiates the exterior surfaces of plastic tubs that contain 100 syringes, with three 150 KeV electron beams. Intense x-ray radiation is an unwanted by-product of the electron beams. The irradiation chamber is contained in a shielded cabinet made of S/S encased ¼” thick lead. Actuated shield shutters that are synchronized with the product transport conveyors provide the x-ray shielding along the product path. Radiation levels outside the unit are less than the 10CFR21 requirement for publicly accessible x-ray system cabinets. The enclosure downstream from the electron beam guns has a built-in hydrogen peroxide vapor decontamination system to periodically sterilize the zone. HEPA filtration is included to achieve a Class 100 or better clean room condition.  Ozone produced by the electron beam passage through the air is exhausted. The purpose of the system is to sterilize the exterior of the syringe packages as they pass into a sterile syringe filling machine. The system is capable of feeding the fastest syringe filling machine: 36,000 syringes per hour.

  • Ton Container Decontamination System

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Ton Container Decontamination System

Project Scope: Fabrication, Mechanical & Electrical Assembly; Integration of Material Handling & System Controls; Leak Testing & System Testing; NFPA 70, UL 508A, ASME NQA-1.

Springs Fab, in partnership with Merrick & Company, provided the fabrication, assembly, and testing services for a custom processing system that would remotely punch, drain, and decontaminate a stockpile of 1,880 bulk containers (Ton containers) filled with mustard agent.  There were twelve (12) stations built and assembled, coinciding with the steps in the processing of Ton containers.  The assembly involved integration of the stations, a punch to penetrate the ½” steel plate wall of a Ton container with a 6” square hole, a pipe cutter to section the drained container, a hot/cold washing station to clean out the cut sections, robotics, conveyors, and all controls (hydraulic, electrical).  Springs Fab and Merrick worked together to coordinate programming issues with the various subsystems, and on system testing (functional and controls). The project required close cooperation at the Project Manager level to maintain a schedule while constructing a system of unusual complexity.

Summary of Schedule and Cost Performance

The project was completed on budget.  The fabrication and assembly were completed on time although the shipment was delayed 6 months to address issues involving out-of-round. Since shipping at the end of 2002, the system was installed at a DoD site, decontamination of all Ton containers was successfully completed, and the system has been decommissioned as planned.

  • Active Powder Ingredient Isolators

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Active Powder Ingredient Isolators

Project Scope: Engineering & Design; Fabrication & Mechanical Assembly; Control System Hardware (UL 508A) and Software; Complete Integration, Testing; GAMP4.

The Active Powder Ingredient (API) isolators are a collection of design build projects, built in partnership with SKAN US, for a major pharmaceutical customer. Isolators are integrated with process equipment so that toxic powders are contained. The projects generally involve isolators, pharmaceutical process equipment modifications, local air handling and filtration, and control system integration. Examples shown here were all delivered to one customer. They are: freeze dryer (center), granulator (upper left), roller compactor (upper right), pill press (lower right), and dispensing isolator (lower left).

  • Aseptic Blow-Fill-Seal Cap Insertion Isolator

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Aseptic Blow-Fill-Seal Cap Insertion Isolator

Project Scope:  Engineering & Design, Fabrication & Assembly, Laminar Airflow Test, Cycle Development, Micro-Biological Qualification, Ammonia Leak Test, GMP 

The Aseptic Blow-Fill-Seal Isolator was developed for a major pharmaceutical OEM. The function of this unit is to sanitize caps and aseptically convey them into a blow-fill-seal molding machine built by the OEM. The isolator provides HEPA filtered laminar vertical airflow, and decontamination of the isolator interior and product. Sanitization is accomplished with an integral vapor hydrogen peroxide (H2O2) system. Materials used are T316L stainless steel and tempered safety glass doors, configured in hinged swing mounts to allow for ease in cleaning and product loading. All controls are self contained, including PLC, blowers, liquid hydrogen peroxide, and software.

Springs Fab designed, fabricated and completed factory acceptance testing. FAT included cycle development of the decontamination system, microbiological qualification with BI indicators, complete laminar airflow tests, and system leak testing. 

The Isolator is offered as an option by the OEM, providing assurance of meeting critical FDA requirements in the operation of a blow-fill-seal molding machine.

  • Cask Process Enclosure

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Cask Process Enclosure

Project Scope:  Engineering/ Design Drawings; Structural Analysis; Fabrication; Mechanical & Electrical Assembly; Disassembly & Shipment. Value: $600,000

Springs Fab was contracted to design and build a Cask Process Enclosure for use in the TRU Waste Processing Center in Lenoir City TN. The enclosure serves as secondary containment in the processing of transuranic waste. It consists of a modular structural steel frame and skin in the form of an outer airlock, inner airlock, process area, drum bagout, and personnel airlock. Deliverables included double pane windows & light panels, push-button roll-up door, bi-fold doors, and bag-out blisters. The facility will process concrete casks inside the enclosure, progressing through the series of airlocks, to a waste removal station where items are size reduced, sorted, and packaged. The interior spans 22’ and is self-supporting with no internal intermediate structure, and operates at a negative pressure. Springs Fab provided the design engineering, fabrication, and complete initial assembly in our facility where the client conducted a factory acceptance inspection.

  • Electron Microscope Lab Shielded Hot Cell

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Electron Microscope Lab Shielded Hot Cell

Project Scope:  Engineering/ Design Drawings; Seismic Analysis; Fabrication; Lead Installation; Final Assembly; Pressure Decay Leak Testing; Functional Testing; ASME NQA-1.  Value: $1,000,000.

The EML Hot Cell was supplied to BEA for support of their Reduced Enrichment for Research & Test Reactors (RERTR) program, used to examine irradiation experiments. Materials can be transported to and from a larger hot cell using a Springs Fab designed shielded container (“Pig”) with a double door transfer port. Master-Slave Manipulators were supplied by BEA, installed and tested by Springs Fab. The cell is heavily shielded with permanent lead and hinge mounted lead glass windows (50 ton, fully assembled). The engineering phase of the project involved production of preliminary design drawings, design review, detailed mechanical and electrical drawings, and structural/seismic calculations. A custom airlock with a sliding tray was part of the design. Springs Fab fabricated the hot cell and Pig, assembled the cell, installed manipulators, and conducted helium leak/pressure decay testing, and functional testing.

  • Restricted Access Barrier System (RABS)

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Restricted Access Barrier System (RABS)

Project Scope:  Engineering & Design, Fabrication & Assembly, Installation

Springs Fab has developed a Restricted Access Barrier System (RABS) product line, to be utilized on appropriate pharmaceutical applications. RABS are a good choice for upgrading sterility in existing aseptic processing cleanrooms. Human operators pose the greatest risk to product contamination and RABS provide an additional barrier between operators and product. RABS are extremely flexible in their utilization and can be easily designed around existing process and filling equipment. The system can either be configured as an “Open RABS” (airflows out bottom) using cleanroom airflow, or integral air handling units; or as a “Closed RABS” (airflow is provided and contained). Standard features include cGMP design, smooth tubing construction, invisible field joints, doors, clean hinges and no gaps. Upgrades available include gloveports, fully interlocked doors, and foot covers over anchors.

Springs Fab recently provided four process lines of RABS to a major pharmaceutical company, accomplishing field survey, design, customized air handling units, fabrication, and installation under an expedited schedule and in close coordination with the customer’s ongoing construction. All deliveries were on time, and the completed system has proven to meet strict regulatory requirements through validation testing by the customer.

  • Integrated Glovebox System

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Integrated Glovebox System

Project Scope: Fabrication; Mechanical & Electrical Assembly; System Integration; Set-Up & Commissioning of Gas Purification System; Leak Testing & System Testing and Documentation; ASME NQA-1.

Springs Fab provided the fabrication, assembly, and testing services in the construction of a $15M nuclear materials handling system. This was accomplished in partnership with Merrick & Company as a design-build project under an extremely tight schedule. The system consists of two large machine tools, enclosed within five major gloveboxes, nine vertical sliding doors, four airlocks, material handling systems and complete environmental controls including system gas purification. Springs Fab was able to complete fabrication, testing, and delivery within the agreed 11-month fabrication schedule in spite of numerous system issues, attributed to close schedule management and also communication with our partner and customer.

 

·         Fabrication of qty (5) gloveboxes, (2) hoods, (9) vertical sliding doors, (4) airlocks, trolley carts

·         Fabrication of two-axis ram sealing interfaces between glovebox and lathe

·         Fabrication of system piping, filter housings, and gas mixing distribution station

·         Construction of a temporary mezzanine to support gas purification systems, power panels

·         Assembly of all systems, including interfaces with two large lathe machine tools

·         Installation of O2 and He monitors, hoists, HEPA filters, piping, and pipe supports

·         Installation of weigh scale, sample pumps

·         Installation, commissioning of qty (3) gas purification systems

·         Electrical assembly of all system wiring (power, instrumentation, power panels, transformer)

·         Leak testing of all gloveboxes, airlocks, and vertical sliding doors, piping

·         System leak testing

·         Functional testing of hoists, pressure relief valves, gas purifiers, trolley carts

·         Integrated system FAT of all equipment

·         Manufactured under ASME NQA-1



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