849_SAM PD.pdf

26-40-1002 29 Sept 2025

DRAFT PURCHASE DESCRIPTION FOR THE ACQUISITION

OF VERTICAL TURRET GRINDING MACHINE

SCOPE.

Scope. The content of this specification describes the minimum requirements for one

(1) Vertical Turret Grinding machine. The contractor shall provide complete turnkey installation services to include all parts, rigging equipment, qualified personnel, materials, delivery, origin and destination testing, full turnkey solutions for repair of LM2500 engine parts including programming, tooling, fixtures, proving-out parts, and training as described in the following specification to provide one (1) fully operational machine located at Fleet Readiness Center Southwest (FRC-SW), in building 472 with door opening size of 17 feet wide and 20 feet high.

APPLICABLE DOCUMENTS. The documents listed in this section are cited in sections 3 and 4 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all requirements of documents cited in sections 3 and 4 of this specification, whether or not they are listed in section 2.

Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

Government Documents.

Specifications, Standards, and Handbooks. The following specifications, standards and handbooks form a part of this document to the extent specified herein.

STANDARDS – FEDERAL

FED-STD-H28B: Screw Thread Standards for Federal Service

FED-STD-313F: Material Safety Data, Transportation Data, and Disposal Data for Hazardous Materials Furnished to Government Activities

U.S Department of Labor, Occupational Safety and Health Administration

(OSHA)

29 CFR 1910: General Industry, OSHA Safety and Health Standards

(Application for copies should be addressed to the OSHA Publications Superintendent of Documents P.O. Box 37535 Washington, D.C. 20013-7535)

Environmental Protection Agency (EPA)

40 CFR 761: Polychlorinated Biphenyls (PCBs) Manufacturing, Processing, Distribution in Commerce, and Use Prohibitions

(Application for copies should be addressed to the EPA Ariel Rios Building 1200 Pennsylvania Avenue, N.W. Washington, DC 20460)

DEPARTMENT OF DEFENSE

U.S. NAVY

OPNAV 5100.23G w/change 1: Navy Safety and Occupational Health Program Manual

(Application for copies of the OPNAVINST should be addressed to Office of the Chief of Naval Operations, The Pentagon, Washington, DC 20350-2000 or to Commander, Naval Safety Center 375 A Street Norfolk, VA 23511 or on the internet at http://www.public.navy.mil/navsafecen)

MILITARY STANDARDS

MIL-STD-130N w/Change 1: Identification Marking of U.S. Military Property Item Unique Identification Marking (IUID)

(Application for copies should be addressed to Air Force Product Data Systems Modernization Standards (TMSS) Office, 554 ELSG/SBP, 4375 Chidlaw Road, Bldg. 262, Room S008, Wright-Patterson AFB, OH 45433-5006, Phone (937) 257- 0870 or 0853 or https://quicksearch.dla.mil/qsSearch.aspx)

Other Government Documents, Drawings, and Publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

LOCAL FACILITY DOCUMENTS

Attachment A: Courtesy Layout – provided on SAM.

http://www.public.navy.mil/navsafecen https://quicksearch.dla.mil/qsSearch.aspx

Non-Government Publications, Specifications, Standards, and Handbooks. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the documents listed in the solicitation or contract shall be the current edition at time of solicitation.

American Gear Manufacturers Association (AGMA)

AGMA ISO 1328-1-B14: Cylindrical Gears - ISO System of Flank Tolerance Classification - Part 1: Definitions and Allowable Values of Deviations Relevant to Flanks of Gear Teeth

(Address application for copies to: 500 Montgomery Street, Suite 350, Alexandria, VA 22314-1581 USA)

American National Standards Institute, Inc. (ANSI)

B11/STD B11: General Safety Requirements Common to ANSI B11 Machines

B11/STD B11.22: Safety Requirements for Turning Centers and Automatic, Numerically Controlled Turning Machines

ASNI B11.9- Machine Tools – Safety Requirements for Grinding Machines (2010 edition)

ANSI B7.- Safety Requirements for Use, Care & Protection of Abrasive Wheels

(Address application for copies to the American National Standards Institute, 11 West 42nd Street, New York, NY 10036)

American Society of Mechanical Engineers (ASME)

ASME Y14.5: Dimensioning and Tolerancing

(Applications for copies should be addressed to ASME International Three Park Avenue New York, NY 10016-5990 or www.asme.org)

International Organization for Standardization (ISO)

ISO 13041-2: Test Conditions for Numerically Controlled Turning Machines and Turning Centres - Part 2: Geometric tests for machines with a vertical workholding spindle

ISO 13041-6: Test Conditions for Numerically Controlled Turning Machines and Turning Centres - Part 6: Accuracy of a Finished Test Piece

ISO 3408-3: Ball Screws- Acceptance conditions and acceptance tests http://www.asme.org/

ISO 4413: Hydraulic fluid power-General rules and safety requirements for systems and their components

ISO 4414: Pneumatic Power-General rules and safety requirements for systems and their components

(Application for copies should be addressed to the International Organization for Standardization (ISO) 1 rue de Varembé, Casepostale56, CH211Geneva 20, Switzerland)

National Electrical Manufacturers Association (NEMA)

NEMA 250: Enclosures for Electrical Equipment (1000 V Maximum)

NEMA MG 1: Motors and Generators

(Application for copies should be addressed to the National Electrical Manufacturers Association, 1300 N 17th Street, Rosslyn, VA 22209)

National Fire Protection Association (NFPA)

NFPA 70: National Electrical Code

NFPA 79: Electrical Standard for Industrial Machinery

(Applications for copies should be addressed to the National Fire Protection Association, ATTN: Support Services, 11 Tracy Drive, Avon, MA 02322)

Order of Precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulation unless a specific exemption has been obtained.

2.4 Acronym Definitions Not Explicitly Listed in Text. The following acronyms not explicitly listed in each section text are defined as follows:

a. JIS- Japanese Industrial Standards

b. DIN- German Institute for Standardization

c. EN- European Standard

REQUIREMENTS.

Design. The item offered shall be new and a current commercially available model. A current model is defined as the manufacturer’s currently produced model which, on the date this solicitation is issued, has been designed, engineered, sold or is being offered for sale through advertisements or manufacturer’s published catalogue or brochures. Products such as a prototype unit, pre-production model, or experimental unit do not qualify as meeting the requirements specified herein. The machine shall include all components, parts, and features necessary to meet the performance requirements specified herein. All parts subject to wear, breakage or distortion shall be accessible for adjustment, replacement, and repair.

Measuring and Indicating Device Graduations. All measuring and indicating devices on the machine shall be graduated in the United States customary units. An electronic control system that demonstrates switching between manufacturer standard units to United States customary units will be found acceptable.

Controls. All electrical, mechanical, hydraulic, and pneumatic operating controls shall be located convenient to the operator's workstation(s).

Safety and Health Requirements. All machine parts, components, mechanisms, and assemblies furnished on the machine, whether or not specifically required herein, shall comply with all of the requirements of OSHA 29 CFR 1910 or equivalent ISO/EN/DIN/JIS standards. The machine and any accessories shall comply with ANSI B7 on the safe handling and mounting of abrasive wheels. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements

Safety Guarding. Covers, guards, or other safety devices shall be provided per ANSI B11.22 and or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

The safety devices shall not interfere with the operation of the machine. The safety devices shall prevent unintentional contact with the guarded part, and shall be easily removed to facilitate inspection, maintenance, and repair of the parts.

Audible Noise Level. Audible noise emitted by the equipment shall not exceed 84 decibels (dB), measured on the “A” weighted scale of a standard Type II sound level meter, at the operator's work position or any point at a distance of three (3) feet from the equipment. Noise generated by the work piece shall be excluded in determining compliance of the equipment with the 84 dB requirements.

Hazardous Material Exclusions. Supplies or materials being provided as part of the equipment shall be free of known hazardous materials. These materials shall not be brought on site without prior approval of the Government. Radioactive materials or instruments capable of producing ionizing radiation as well as materials which contain asbestos, mercury, lithium, methylene chloride, lead (= or >0.06%), or polychlorinated biphenyls (PCB’s) are prohibited. Definitions of hazardous materials are specified in the latest version, including revisions adopted during the term of the contract, of FED-STD-313F.

Nickel Metal Hydride and lithium batteries are permissible for memory backup. Class I Ozone Depleting Substances as defined in 40 CFR 82 shall not be used in the performance of this contract or be provided as part of the equipment. Exceptions to the prohibition of these materials must be referred to the Contracting Officer in writing, for consideration, not later than 60 calendar days after effective date of contract and prior to any work being performed.

PCB Certification. Written certification from the manufacturer that the equipment contains no detectable PCBs (less than two (2) parts-per-million) shall be provided. The certification shall be on manufacturer’s letterhead, and signed by a company official who is empowered to provide the same.

Environmental Protection. Under the operating, service, transportation, and storage conditions described herein, the machine shall not emit materials hazardous to the ecological system as prohibited by Federal, state, or local statutes in effect at the point of installation.

Lubrication. Means shall be provided to ensure proper lubrication for all moving parts in accordance with manufacturer requirements. All oil holes, grease fittings, and filler caps shall be easily accessible.

Recirculating Lubrication. When the machine is equipped with a recirculating lubrication system, it shall include a filter that is cleanable or replaceable. Each lubricant reservoir shall have at least a 24-hour capacity. Means shall be provided to indicate a low lubrication condition. When a low lubrication condition occurs, the machine shall complete the current operation and come to a complete stop. The machine shall indicate that lubrication is required.

Lubrication Data. The Contractor shall provide the following information on all liquid or grease lubricants contained within equipment/system or in balk (5 gallons or more) supplied under this procurement.

a. Liquid Lubricants

i. Viscosity grade in ISO units

ii. Viscosity Index

iii. AGMA and/or SAE classification as application

iv. Mil Spec and/or NATO Code as applicable

v. Viscosity in Centistokes (cst) @ 40° C and 100° C

vi. Type Additive package. Example: ZDDP, Rust inhibitors, Foam inhibitors.

vii. Neutralization, the TBN (alkalinity) and/or TAN (acidity)

viii. Flash point

ix. Pour point

b. Grease Lubricants

i. National Lubrication and Grease Institute (NLGI) Number

ii. Type and percent of thickener

iii. Dropping point

iv. Maximum Service Temperature

v. Base oil viscosity range in SUS or centipoise

Replacement Parts. All parts subject to replacement shall be manufactured to definite dimensions and tolerances. Replacement parts shall be interchangeable without requiring modification. Replacement parts are those that are subject to wear or failure such as gears, bearings, shafts, feed screws, drive belts, pumps, and seals. Electrical replacement parts shall include but not be limited to, motors, relays, fuses, switches, magnetics, pushbuttons, light bulbs, braking mechanisms, and solid-state devices. Tooling and accessories normally supplied as standard items shall also be considered replacement parts.

Foreign-sourced replacement parts shall either be interchangeable with domestically supplied components or be readily available from a domestic source.

Construction. The machine shall be constructed of parts that are new, without defects, and free of repairs. The structure shall withstand all forces encountered during operation of the machine to its maximum rating and capacity without distortion.

Castings and Forgings. All castings and forgings shall be free of defects, scale, and mismatching. No processes such as welding, peening, plugging, filling with solder or paste shall be used for reclaiming any defective part.

Fastening Devices. All screws, pins, bolts, and other fasteners shall be installed to prevent unintentional loosening. Fastening devices subject to removal or adjustment shall not be permanently installed.

Threads. All threaded parts used on the machine and its related attachments and accessories shall conform to FED-STD-H28B and the applicable “Detailed Standard” section referenced therein or equivalent ISO/EN/DIN/JIS standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Hydraulic System. Under the condition that a machine has a hydraulic system, the system shall conform to ISO 4413. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls. A machine that does not require a hydraulic system to operate properly shall be considered acceptable.

Pneumatic System. Under the condition that a machine has a pneumatic system, the system shall conform to ISO 4414. The system shall be complete, including all pumps, valves, piping, cylinders, and pressure controls. A machine that does not require a pneumatic system to operate properly shall be considered acceptable.

Gears. All gears of axis drive trains shall conform to or exceed all provisions of ANSI/AGMA ISO 1328-1-B14 (PESO). All gears shall be of proper width and size to transmit full-rated torque and horsepower throughout the speed ranges without failure for the expected service life of the machine. Gears in drive trains shall be hardened and ground steel.

Surfaces. All surfaces shall be clean and free of harmful or extraneous materials. All edges shall be either rounded or beveled unless sharpness is required to perform a necessary function. The condition and finish of all surfaces shall be in accordance with the manufacturer's commercial practice.

Welding, Brazing, or Soldering. Welding, brazing, or soldering shall be employed only where specified in the original design. None of these operations shall be employed as a repair measure for any defective part.

Painting. The machine shall be painted in accordance with the manufacturer’s commercial practice. All paint shall be of the lead-free type.

Workmanship. Workmanship of the machine shall meet all requirements specified herein and shall be of a quality equal to that prevailing among manufacturers producing equipment of the type covered by this purchase description.

Components. The machine shall consist of not less than the following components:

Base. The base shall be a stress relieved, heavy duty, ribbed casting or steel weldment having characteristics that minimize both thermal and vibration effects, while providing the strength and size to assure maximum rigidity and support for any load within the rated capacity of the machine. Means shall be provided for accurate, ease of leveling.

Rotary Table. The worktable shall be a casting of iron, or iron alloy, internally ribbed and proportioned to support and withstand the maximum capacity work-piece weights and tool thrust loads. The top of the worktable shall be machine finished for a work mounting surface. The machine shall have a rotary table that is at least 80 inches in diameter. The table bearings shall be preloaded, antifriction, with a high running accuracy.

The worktable surface shall be precision machined. The table shall be rating on a large dimensioned thrust bearing, angular bearings for radial guidance. The table shall have T-slots and the number and size of T-slots shall be the manufacturer’s standard.

Axes. All axes of the machine shall be actuated through a closed loop, high-gain electrical servo mechanism driving re-circulating ball screws and nuts conforming ISO 3408-3. Infinitely variable feed drives shall be provided for all axes. Axes shall be machined to accept way bearing of a precise fit to their respective ways. The way bearings shall be an antifriction type and shall be provided with adjustable gibs, guides, or bearings to maintain and adjust alignment of the table to the ways and prevent causing excessive loading of the feed drive motor. Antifriction and re-circulating ball type linear ways are acceptable. Axes description shall conform to EIA-267C (PESO).

Grinding Spindle.

The spindle shall be equipped with ultra-precision pre-load bearings and shall be precision balanced. A precision balanced AC motor shall be incorporated in the spindle. The spindle shall be designed to dampen all vibration produced by the machine. The spindle shall be designed for operations in both dry and wet cutting.

Part Measuring System.

The machine shall have a part measuring system including measuring probe and laser. The system shall measure the following component features: internal and external diameter of the parts, height differences, face runout, and taper error. The measuring system shall inspect the inner diameter surface for the following component feature: radial runout, max, min and average diameter, and roundness. In addition, the part measuring system shall measure LM2500 parts listed in table II for the repair process including the vanes inside of the stator case. Vendor shall provide measuring programs as part of the LM2500 repair turnkey. The vendor shall provide probe DG50BP or equivalent to measure the lands and probe DG10BP or equivalent to measure the vanes.

Handheld Pendant.

An operator’s handheld pendant type control shall be provided with the machine. The pendant control shall include all functions and operating devices for setup and manual operation, including but not limited to the following.

a. Emergency Stop

b. Mode Selection

c. Feed Rate Override

d. Manual pulse generator, capable of controlling individual axes

e. Incremental feed selection

f. LED for axis position and information

Computer System.

All machine program data and measurement results, that the system generates shall be capable to be archived to a storage media and be accessible from FRCSW computer and have the capability to print data. The contractor shall provide a government approved, along with the machine, any respective custom software/licenses required to perform all related functions to the operation of the machine. The computer’s specifications shall be provided for optimal performance of system’s requirements. The contractor shall submit the computer’s specifications thirty (30) calendar days After Contract Award (ACA) for Government review and approval.

Door. Manually operated doors shall be fitted at the front of the enclosure. The doors shall be designed so that a component can be loaded and unloaded from the machine using an existing overhead hoist. Manual doors shall be locked when in operation.

Coolant System. A flood type coolant system shall be provided. The coolant system shall include a sump or reservoir, a power-driven pump, and all necessary piping. The system shall have means for draining and cleaning. Means shall be provided to permit the operator to direct and control the amount of coolant over the entire work area. Coolant pumps shall be actuated by software user interface. Coolant output shall be programmable from the CNC part program in gallons/min. All coolant pump outputs shall be monitored for pressure, temperature and flow and displayed on the operator screen. Coolant levels shall be monitored in all coolant holding tanks. The level shall be monitored for extreme high level and an alarm initiated as well as audible alarm if a high level is reached. Fail safe valves shall be provided to prevent overflow if power is turned off to the machine or a fault is generated.

• Coolant Type: Grindex 35S

• Coolant filtration system shall be provided with the tank capacity to sustain a flow of 40 gal/min.

• Coolant shall be temperature controlled by the machine to maintain 70 degrees

Fahrenheit with +/-2 degrees.

• Coolant system with the following process pumps:

o Honeycomb debur (15 micron) o Wheel scrubber (15 micron) o Part (15 micron) o Table/Grind fixture (5 micron)

• Coolant spray nozzles should be constructed of stainless steel, brass or corrosion resistant metal.

• Coolant nozzles must be adjustable and allow for proper alignment of coolant spray into contact zone of grinding wheel and workpiece

• Coolant Tank Capacity: 300 gallon

• Flood Coolant Pressure: 50 psi

• Coolant Splash Guard

• Filtration system

• Magnetic Separator

• Mist Collector

• Chiller system

Electrical System. The machine shall conform to NFPA 79 or current equivalent

ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements. The existing source power available at the facility is 480 volt, 3-phase, 60 Hertz (Hz), 270 amps Delta configuration. The machine’s electrical system shall be tolerant of fluctuation of ± 10 percent. The electrical system shall be complete, including any electrical transformer(s) that may be required to modify the existing source voltage to the proper operating voltage of the equipment. A properly rated, and fused, single disconnect device shall be utilized on the machine with means of lockout in the off position only.

Electrical Enclosures. Construction of the electrical enclosures shall be in accordance with NEMA 250 type 12 or current equivalent ISO/EN/DIN/JIS/IEC standards and shall provide for ventilation of components and shall be designed for an indoor non-hazardous location. All electrical components shall conform to NFPA 79 or equivalent ISO/EN/DIN/JIS standards. The machine shall be provided with interlocks on its electronic cabinet that shall instantly remove power from the equipment when the door is opened in accordance with NFPA 79 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Arc Flash Protection. The machine enclosures shall be marked for arc flash in accordance with NFPA 79 Paragraph 16.2.3 “Safety Signs for Electrical Enclosures” or current equivalent ISO/EN/DIN/JIS/IEC standards for arc flash safety. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Solid-State Components. Electrical devices used to power electrical servo and spindle motors of control voltage delivered to solid-state electrical components shall be solid-state devices. Such devices shall be equipped to handle the electrical load imposed by operation of the machine to its maximum potential. The use of selenium in solid-state components shall be restricted to those devices that protect other solid-state components from voltage surge.

Computer Numerical Control (CNC) Features. The machine shall be equipped with CNC control incorporating all standard features. The CNC unit shall provide programmable automatic control of machine functions, operating modes, axis movement and other part program directed functions for the machine. Movement in all axes shall be both synchronous and independent positioning. Control features shall include Manual Data Input (MDI), simultaneous control of all axes, linear interpolation, circular interpolation, programmable interface, part program edit, part program storage, background editing function, fixed cycles, and control diagnostics. The CNC shall direct machine functions from command data stored in memory. The data stored in memory shall be input by the media specified herein. The control shall initiate a halt and error signal should a fault condition occur in the control. The control shall automatically shut down when internal operating temperatures exceed safe operating limits. The CNC controller with incorporated display screen, keyboard, and pointing device shall be located on a swing away pendent capable to movement to and away from the enclosure opening.

CAM Software. Computer Aided Manufacture software shall be provided by manufacture to aid in the creation of G-code programs or a Post Processor shall be provided, that is compatible with at least NX 2312 CAM software and/or latest version for all relative machining functions.

Motors. Motors shall be rated for continuous duty. Alternating-current (AC) motors shall be designed to operate on 60-Hz and each motor enclosure shall meet the requirements for a drip-proof enclosure. All motors shall meet the requirements of NEMA MG-1 or current equivalent ISO/EN/DIN/JIS/IEC standards. At the time of proposal, the vendor shall indicate which document they will utilize for compliance to the requirements.

Each motor shall have an identification plate in accordance with paragraph 3.7 to identify manufacturer, model number, serial number, voltage, amperage, horsepower, phase, frequency, and frame number. Motor horsepower shall be the manufacturer’s standard or standard optional horsepower as indicated on the manufacturer's design and construction drawing(s).

Work light. A work light, whether built-in or added on, shall be provided. The light shall have a protective shield and provide maximum light to the work area.

Facility Connections. Electrical connections made to the facility electrical system shall conform to NFPA 70.

Hour Meter. The machine shall be equipped with a non-resetting type, hour meter to display accumulated operating time of the drive motor(s), mounted on the main electrical panel visible from the outside, sealed to prevent the entrance of dust and moisture, and shall be mounted to withstand shock and vibration generated by the machine.

The meter shall have a range of 0 to 99,999.9 hours in increments of one (1) tenth of one

(1) hour. A CNC control that tracks and displays total machine on time (a non-resetting type), controller on, program runtime, and run time of the servo motor(s) shall be considered to meet this requirement. The meter shall be sealed to prevent the entrance of dust and moisture and shall be mounted to withstand shock and vibration generated by the machine.

Size and Capacity. The size and capacity of the machine shall be not less than specified in Table I.

Table I: Machine Characteristics Swing Diameter 85 in Part Height Clearance1 68 in Workpiece Weight 4,000 lb Grinding Depth 68 in Turning Depth 68 in Z-Axis Travel: 78 in

Rotary Table (C-axis) Diameter 80 in.

Speed 150 rpm

Spindle Max Speed 4,000 rpm Tool Holder HSK 100 Grinding Spindle Profile grinding for stator case vanes and surfaces at different angles

Other Requirements:

Full Turnkey for Repair Programs for LM2500 Engine Parts including programming, tooling, supporting equipment, set ups, and prove outs

Automatic Tool Changer with tool storage 15 tool capacity Maximum Grinding Wheel Diameter 14 in.

Maximum Grinding Wheel Width 3 in.

Power Requirement 480 V - 3 phase - 60 Hz with 270 Amp.

1 Part Height Clearance refers to the maximum height of 68 inches of the stator case with its fixtures that can be machined inside. The part height clearance must be from the working table to the end of tip of the tool needed to grind or turn internal diameter of the stator case.

Alignment and Accuracy Tolerances. The alignment and accuracy tolerances of the machine shall be measured in ISO13041-2 Geometric test for machine with a vertical workholding spindle.

Standard Tooling and Equipment. All standard tooling and equipment required for proper operation and maintenance of the machine shall be provided. A list of these items shall be furnished at time of proposal.

a. Tool Probe System

b. Part Probe System

c. Gap Elimination System

d. Wheel Balancer System

e. Wheel Rotary Dresser

f. Gravity Bed filtration unit

g. Chip conveyor

3.6.1 Programming / Supporting Equipment. The software with CNC grinding and turning repair CAM and G-code programs, and the respective supporting equipment shall be provided by the contractor with the machine to repair LM2500 engine parts.

Grinding and turning repair programs shall not be locked and be accessible for future modifications when needed by FRCSW.

Contractor shall provide supporting equipment from Rhinestahl (GE’s certified supplier) with cage code: 5QE71

Rhinestahl supporting equipment number for the repair of LM2500 engine parts are listed in table III.

Table III: List of Supporting Equipment for LM2500 Base Engine Repair Description Tool Number

Front Stator Case Holding fixture 2C6544P02 Front Stator Case Restraining fixture 2C6544P03 Tool A carbide tool (Kenmetal TNMS-332-K68

Insert and a Carboloy TJL-16-3 holder) with a nose radius of 0.040-0.050 inch and a 10-degree positive rake; or equivalent

Tool Carboloy Grade 883 with 6-8 degree positive rake angle and 0.062 inch nose radius, or equivalent

Rear Stator Case Gage 2C6547G01 Rear Inspection gage and Gage master 2C6547P02

Front Stator Gage Set and Gage Master 2C6545P02 or equivalent Front Stator Gage 2C6553 or equivalent Fixture Set, Machining - Compressor Front Stator

2C6544G01

Fixture Set, Machining - Compressor Rear Stator

2C6546G01

Fixture (Grinding), Restraining, Bottom 2C6504P37 Fixture (Grinding), Restraining, Upper 2C6504P39 Vane Angle Protractor 2C6103 Vane Position Fixture Set 2C6178G09 Vane Snubber Set 857E729P Stages 8-9 Manifold Opening Protractor 1C5659 Casing Lift fixture 1C5976 Vane Slot Repair Inspection Gages - For LM2500 Base Engine STAGES 7-16

2C7349; or equivalent

Vane Slot Repair Tool Set - For LM2500 Base Engine STAGES 7-16

2C7333; or equivalent

Vane Slot Repair Restraining fixture - For LM2500 Base Engine

2C7041G01

Vane Slot Repair fixture - For LM2500 Base Engine

2C7042G04

Tool Mini mic. (Mitutoyo Series 146102 or 146104, MTI Corporation, 2025 Onne Rd., Elk Grove Village, IL 60007); or equivalent

Fixture Set, Machining - C/R Spool, Stages 3-9

2C6537G07

Upper Ring - C/R Spool, Stages 3-9 2C6537P06 Spool Stages 3-9 Gage 2C6540 or equivalent

Fixture Set, Machining - C/R Spool, Stages 11-13

2C6538G01

Hold Down - C/R Spool, Stages 11-13 2C6538P03

Fixture Set, Machining - C/R Spool, Stages 14-16

2C6539G01

Hold Down - C/R Spool, Stages 14-16 2C6539P03 Spool Stages 11-13 or equivalent 2C6541 or equivalent Spool Stages 14-16 or equivalent 2C6542 or equivalent

2nd Stage Nozzle, Fixture, Grinding - HPT Shrouds - For LM2500 Base Engine -

APPLICABLE FOR SST

2C6552G04

2nd Stage Nozzle, Hold Down Fixture - HPT Shrouds - For LM2500 Base Engine -

APPLICABLE FOR SST

2C6552P03

Equivalent fixtures or inspection gages to be approved by FRCSW LM2500 Engineering team

Marking on Instruments, Control Panels, and Plates. All words on plates shall be in the English language. Characters shall be engraved, etched, embossed, or stamped in boldface on a contrasting background. All plates shall be corrosion resistant.

Lubrication Plate. A lubrication plate shall be permanently and securely attached to each machine. The plate shall contain the following information.

Points of Lubricant Application Servicing Interval Type of Lubricant Viscosity

Military or Federal Specification for Each Lubricant (If available) Size and Type of Each Lubricant Filter

Nameplate. A nameplate shall be permanently and securely attached to each machine. The nameplate shall contain the information listed below. If the machine is a special model, the model designation shall include the model number of the basic standard machine and a suffix identified in the manufacturer's permanent records.

Nomenclature Manufacturer’s Name Manufacturer’s Model Designation Manufacturer’s Serial Number Power Input (Volts, Total Amps, Phase, Frequency) Contract Number Date of Manufacture

Identification Marking of Military Property. An Item Unique Identification

Marking (IUID) shall be provided in accordance with MIL-STD-130N and all applicable documents within the standard with Machine Readable Information (MRI) for item identification marking and automatic data capture. The application of Human Readable Information (HRI) shall be used in combination with MRI and free text. At a minimum this tag shall contain the information listed in paragraph 3.7.2 Nameplate.

Technical Data. Three (3) hard copies and two (2) electronic copies technical data shall be provided with the machine. Technical data shall contain specifications, instructions for the operation, maintenance of the machine and recommended spare parts list. All copies of technical data shall be legible and written in the English language.

a. Electrical Schematics: Detailed diagrams showing the electrical setup, wiring, and components for the machine’s control systems and power supply.

b. Spare Parts Lists: A list of recommended spare parts with part numbers, descriptions, and quantities that are usually needed for maintenance or repairs.

c. Consumable Lists: A list of materials like lubricants, cutting tools, and other consumables required for the machine's operation.

d. Drawings: Mechanical and assembly drawings (2D and 3D) to support understanding of machine's structure, layout, and how it fits into our current setup.

e. Warranty Information: Details on the warranty, including coverage, duration, and exclusions.

f. Principle of Operation: Description of how the machine works, covering key operating principles, modes, and setup instructions.

g. Operational Manual: A user manual with step-by-step instructions for setting up, operating, and troubleshooting the machine.

h. Maintenance Manual: A manual with recommended maintenance steps, schedules, and instructions for part replacements.

Plan of Action and Milestones (POA&M). The contractor shall provide a POA&M to identify contractor performance dates of all major events from contract award to completion of all contract requirements. The initial POA&M shall be delivered thirty (30) calendar days After Contract Award (ACA). The milestones shall be prepared using a recognized project management technique (preferably Microsoft Project). The Government and the contractor shall review the report on a monthly basis. The contractor shall notify the Government prior to making any changes to the POA&M. All changes to the POA&M shall be approved in advance by the Government. The POA&M shall detail such items as engineering, procurement of major hardware, assembly, operational debug, factory acceptance, shipment, installation, training, and final acceptance test.

Acceptance Test Plan (ATP). The Contractor shall prepare an Acceptance Test Plan (ATP). The ATP shall be a step-by-step written instruction on how to verify compliance during Contract Quality Assurance Inspection and the Final Inspection/Acceptance Test specified in Sections 4.4 and 4.5. The Contractor shall develop and provide dimensioned drawings of the proposed test part specified in Paragraph 4.7.2. The Manufacture’s standard testing procedures shall be included in the ATP. Any procedures necessary for compliance with Section 4, which are not covered by the Manufacturer’s standard testing procedures, shall be identified and included in the ATP. The initial ATP shall be submitted thirty (30) calendar days ACA for Government review and approval. The accepted test procedures shall become part of this contract.

Installation. The contractor shall be responsible for all equipment (forklifts, man lifts, etc.) and qualified personnel for unloading, rigging, installation, anchoring, connecting machine to utilities, leveling the machines in place, and commissioning of all equipment in order to make it operational. The contractor shall provide the necessary anchor bolts, leveling screws, and related hardware to secure the machine’s components to a foundation. The contractor shall follow the customer’s hours of operation; 6:00 am to 2:30pm, Monday through Friday excluding all national holidays, unless informed otherwise. The contractor shall be responsible for implementing a dust/debris control plan as users will be occupying the space during the work. A mitigation plan needs to be provided to FRCSW. Machine shall be installed in a pit when machine’s height is equal or higher than 18.5 ft. In addition, machine’s table shall be centered to the overhead hoist so that a component can be loaded and unloaded from the machine.

3.8.3.1 Grating, Support Structure and Toeboards. As defined in CFR 1910 Subpart D, §1910.21 walking-working surfaces (i.e. the grating walkway) shall not have a hole, gap or void >2 inches in its least dimension or an unprotected edge >4 feet above the lower basement level. The grating, supporting I-beams, and toe boards need to be added or modified to meet this requirement. Grating, support structure and toe boards need to be added to cover openings exposed. Any new I-beam grating support shall be coated with an epoxy primer and topcoat to match the color of the existing grating support beams.

Installation of walkways shall comply with OSHA minimum walking/working surface width requirements (see OSHA standard referenced in Section 2.1.1).

Foundation. The contractor shall be responsible for providing a foundation for the machine. The contractor shall remove the present foundation and excavate to provide a new foundation that meets all the manufacturer requirements for the machine provided. All demolished and excavated concrete shall be removed and disposed of by the contractor.

The contractor shall provide FRCSW Building 472 with samples, test reports, and curing times for the concrete and epoxy. The government shall be responsible for testing the soil for hazardous materials. When it is determined that hazardous materials have been found, the Government shall be responsible for the disposal of the soil. When no hazardous materials are present then the contractor shall remove and dispose of the soil. Contractor shall be responsible for conducting a ground penetrating radar scan of all area's penetrations will be made below the existing floor. The scan will look for the presence of any utilities in the area that will be disturbed. During the demolition, excavation, and installation the contractor shall be responsible for providing containment and mitigation of dust, debris, fumes, or other emissions that will interfere with operations in adjacent shop areas. In addition the following must be incorporated into the existing or new foundation.

• Secondary Containment. The secondary containment system either a pit or a containment system shall hold 110% all liquids within the equipment in the event of a spill, leakage, release, or malfunction of the equipment where liquids are released on to the floor.

• Epoxy Floor. contractor shall clean the area and apply industrial epoxy. The epoxy shall not exceed 5-feet over the equipment footprint. The type of epoxy used shall be Stonhard GSGS4PA7-5

Geotechnical Survey. When the Government does not provide the underground utility locations of the installation area, the contractor shall perform a geotechnical survey to determine if and where there are any hidden utilities in the location of the current foundation. The contractor shall provide a copy of the completed survey to DLA.

Lead and Asbestos Testing. The Contractor shall be responsible for conducting an onsite survey for Lead Based Paint (LBP) and Asbestos Containing Material (ACM).

The onsite survey shall be completed within thirty (30) calendar days ACA, coordinate with the Contracting Officer. The facility has a known presence of LBP and ACM. A (Virginia, North Carolina, etc.) state the facility is located in) accredited Asbestos Inspector shall perform the onsite survey for Lead and Asbestos to identify any suspected material that appears to be involved in the project. Assume the presence of asbestos and lead paint is a possibility and be prepared to do some sampling and analysis. Provide a signed report certifying the inspection. State the findings of the inspection and state if the area appears to be asbestos free or present the results of the sampling and analysis. The report shall be certified by the Asbestos Inspector and include the Inspector's certification number. Show locations of any samples taken in the report and on the Installation Plan. If either of these two substances are found in areas that will be disturbed by the Installation, and will pose a health and safety threat, the contractor must notify the contracting officer.

The contractor is not required to remove or abate the lead and asbestos under this contract.

Installation/Foundation Drawings (Preliminary Submission). No later than sixty

(60) working days after effective date of contract, installation-drawings shall be provided with soft metric measurements using the manufacturer’s standard format. An electronic copy shall also be provided in DWG or DXF format and download to AutoCAD 2023 version. The Government shall notify the contractor in writing within ten (10) working days of receipt of drawing if they comply with this specification. If revisions are required, the contractor has ten (10) working days to make revisions and resubmit for a new review.

Rejection of drawings does not relieve the contractor from final delivery date of contract performance period.

Installation/Foundation Drawings (Final Submission). Submission of final drawings shall be no later than sixty (60) calendar days of Government acceptance of preliminary drawing. These final drawings shall bear a complete title block with a permanent drawing number, signature, date, and an original stamp or seal of a California licensed Professional Engineer (PE) licensed in the state of the receiving activity where the equipment will be installed. The final drawing submission shall include an engineering report with structural calculations used in the design. The engineering report shall also be stamped by a California licensed PE. The Government shall notify the contractor in writing within ten (10) working days of receipt of drawing if they comply with this specification. If revisions are required, the contractor has ten (10) working days to make revisions and resubmit for a new review. Rejection of drawings does not relieve the contractor from final delivery date of contract performance period

Field Supervisor. The contractor shall provide a full-time (start of installation to final acceptance) field supervisor to direct installation and testing of the supplies. The field supervisor shall have full authority to implement field decisions expeditiously. Work shall not be performed when the field supervisor is not in the immediate work area. The field supervisor shall be identified to the receiving activity prior to the start of installation. The field supervisor shall be fluent in the English language. The field supervisor is required to coordinate with the (DGR) Designated Government Representative for any security clearances for all contractor personnel expected to perform on-site work

Work Stoppage. For unforeseen issues that are found during installation of the foundation, the contractor shall notify the facility point of contact (POC) and DLA immediately to determine further course of action.

Training. After satisfactory completion of acceptance testing of the system, the services of a qualified representative(s), who is proficient in the English language, shall be provided for specialized training to familiarize Government personnel with the equipment and to help ensure reliable performance and maximum service life, during normal usage.

The training shall be for five (5) operators, three (3) programmers, three (3) engineers.

Training shall be performed at the Government facility and shall not be less than five (5) consecutive eight (8) hour workdays, between 6:00 am and 2:30 pm excluding weekends and federal holidays. The course shall utilize as-built drawings and manuals provided under this contract and shall include both classroom and hands-on portions. All printed training aids shall be supplied for the course, be in the English language, and become the property of the Government.

The training shall include the following:

a. Operators Training

b. CAM Programming Training

c. Maintenance Training

d. Mechanical Training

e. Electrical Training

f. Mechanical/Software Engineering Training

g. LM2500 engine parts repair program to operators and MRO engineers including setup fixtures, tooling and parts, run repair programs, machine part, prove out parts.

QUALITY ASSURANCE.

Responsibility for Inspection. The contractor shall be responsible for the performance of all inspection requirements specified herein and in accordance with the attached Quality Assurance Provision (QAP). Except as otherwise specified in the contract or purchase order, the contractor may use his own facility for the performance of the inspection requirements specified herein, unless disapproved by the Government. The Government reserves the right to witness any inspections set forth in the purchase description where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements.

Responsibility for Compliance. All items must meet all the requirements of sections 3 and 4.

Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. Contract quality assurance inspection (Origin) (see 4.4).

b. Final Inspection/Acceptance test (Destination) (see 4.5).

Inspection Conditions. All inspections, tests, and examinations shall be performed in an indoor facility with ambient temperature conditions in the range of 55° F to 100° F and 10% to 95% relative humidity.

Contract Quality Assurance Inspection (Origin). Contract quality assurance inspection shall be applied at the contractor’s facility prior to being offered for acceptance under the contract. The machine and all peripheral equipment added to the machine shall be fully assembled and perform all functions in accordance with this specification. Quality conformance inspection shall consist of the examination in 4.6 and the tests in 4.7.1, and

4.7.2 The machine shall pass the examination, all tests, and contract quality assurance inspection to be acceptable for shipment.

Final Inspection/Acceptance Test (Destination). Final Inspection and acceptance test shall be performed on the machine to ensure conformance with this purchase description.

The acceptance test shall be performed only after the machine is installed at its final location. The acceptance test shall consist of the examination in 4.6 and all tests in 4.7. The machine shall pass the examination and all tests to be accepted.

Examination. The equipment shall be examined for design, dimensions, construction, materials, components, electrical equipment and workmanship to determine compliance with the requirements of this specification.

Tests. Unless otherwise specified within this document, all programs, instruments, materials, material handling equipment, qualified personnel, and tools required to perform and evaluate the tests shall be furnished by the contractor. All measurement tools and indicating devices shall be calibrated in accordance with the attached QAP. If a malfunction occurs during the test, the test shall be restarted each time until all tests in 4.7 are completed without a malfunction. Three (3) consecutive failures without completion of the test may be considered cause for rejection of the system. For the purpose of this test, a “failure” is defined as any equipment malfunction which requires remedial action to restore the system to full operation in accordance with this specification.

Alignment and Accuracy Tests. Tests shall be conducted to ensure the machine meets the alignment and accuracy tolerances specified in paragraph 3.5. The machine repeatability and accuracy for slide motions, turret indexing, spindle speed changes, feed rate changes and auxiliary functions shall be checked.

Operational Test. The machine shall be operated under CNC at no-load for not less than four (4) hours. During operational testing the control functions and machine response to commands for slide motions, turret indexing, spindle speed changes, feed rate changes and auxiliary functions shall be checked. The machine shall be run in each mode of operation (Manual and Automatic) to test the machine’s response to command data. Three

(3) failures in a row to complete the run test may be cause for rejection of the entire system. After successful completion of the operational test, proper operation of all controls, motors, adjusting mechanisms, over-travel limits (programmed stops and hard stops), emergency stop devices, and accessories shall be verified.