DRAFT LPC 2nd and 3rd Stage Vanes SOW.docx

Low Pressure Compressor (LPC) 2nd and 3rd Stage Vanes Modification Statement of Work Period of Performance: Base year and four one-year option years POP 01 July 2023 – 30 June 2028 A. SCOPE: The purpose of this contract is for the cleaning and resurfacing of Low Pressure Compressor (LPC) Stage 2 and 3 vanes, and application of hard coating to the inner platform side faces IAW Accessory Change 1378 Rev 3 (AYC 1378, REV 3).

B. REFERENCES:

(a) A1-F402B-SPM-000 Rolls Royce Maintenance Manual 1 February 2002

(b) A1-F402B-MMI-210 WP 066 00 Cleaning, Inspection and Repair of LP Compressor rotor Blades and Vanes

(c) A1-F402B-MMD-300

C. AFFECTED PARTS

Pre AYC1378 P/N

AYC1378

P/N

D. SUPPORT EQUIPMENT

Fixtures locally manufactured to the specifications as delivered in Engineering Change Proposal (ECP) 3852, LPC 2/3 Vanes Hard Coating

E. GENERAL PROCEDURES

1. 1.0 The Government will ship LPC Stage 2 and 3 vanes to the contractor for modification and rework. The contractor shall inspect all vanes and make a determination per SOW as to which vanes are suitable for recondition, as defined by subject statement of work. The modified vanes shall be returned to the government according to the delivery schedule specified by each delivery order. Vanes that are inspected, as part of the process, and determined to be beyond economical modification shall be marked as scrap and returned to the Government with information on the scrap sticker identifying the cause for rejection. The contractor shall provide monthly reports to the FRC East, DLA Aviation coordinator for the F402 program that includes the vane serial numbers on the report for each vane processed as modified/reworked assets or as rejected/scrapped assets. The report (CDRL A001) shall also include the details defining the cause for any rejected vane.

2.0 The contractor shall perform all cleaning, inspections, and repairs in accordance with (IAW) reference (a), WP 012 03, reference (b), WP 066 00, and reference (c), WP 023 00 and WP 023 01, prior to proceeding with the modification processes.

F. MODIFICATION PROCEDURE

1.0 The contractor shall perform all cleaning, inspections, and repairs (IAW) reference (a), WP 012 03, reference (b), WP 066 00, and reference (c), WP 023 00 and WP 023 01, prior to proceeding with the resurfacing recondition processes. The following alternate processes may be substituted where applicable:

a. Alkaline Clean, J84AL, Omat 173J, as alternate to CM2, reference (a) refers.

b. Electrolytic Stripping per SPI: 5.2001, SPI 5.2008, and SPI 5.2009, as alternate to RM3, reference

(a) refers.

c. Inspect per SPI 5.2002, as alternate to IM6, reference (a) refers.

d. Alkaline Clean Super Bee 300LF, Omat 1/24R, as alternate to CM2 and CM16, reference (a) refers.

2.0 Modify LPC Stage 2 vane side face, paragraph C refers.

a. Locate Vane to grinding fixture, F31690, paragraph D refers, and to a suitable machine. Set true and secure.

b. Locate Datum A, Figure 1 refers. Finish machine as necessary, the inner platform side face to produce 0.686/0.692 in. before flame plating dimension from datum A, Figure 2 refers.

c. Remove burrs and sharp edges using hand tools as necessary, GRP1, GRP2, reference (a), WP014 00 refers.

3.0 Dimensionally inspect LPC Stage 2 vane inner platform side face using G40415, paragraph D refers.

4.0 Modify LPC Stage 2 vane side face, paragraph C refers.

a. Locate Vane to grinding fixture, F31689, paragraph D refers, and to a suitable machine. Set true and secure.

b. Locate Datum A, Figure 1 refers. Finish machine as necessary, the inner platform side face to produce 0.306/0.312 in. before flame plating dimensions from datum A, Figure 2 refers.

c. Remove burrs and sharp edges using hand tools as necessary, GRP1, GRP2, reference (a), WP014 00 refers.

5.0 Dimensionally inspect LPC Stage 2 vane inner platform side face using inspection fixture, G40414, paragraph D refers.

6.0 Locally crack detect inner platform side faces using IM6, as per reference (a), WP 011 03.

7.0 Perform bead peen RP7, for preparation of the inner platform side face surfaces, marked BB, Figure 2 refers, all over as specified in reference (c), WP023 00, to the following criteria.

a. Blast Media: MIL-S-13165:165, Ceramic beads meeting SAE-J1830

b. Blasting intensity: Almen strip, Type N, arc height: 0.015 in. – 0.020 in.

c. Coverage: 200 percent.

8.0 The following operation is to be carried out by the Contractor.

a. Mask off all over except surfaces marked BB (inner platform side faces), Figure 2 refers.

NOTE:

1. Minimum coating thickness measured no less than 0.004 in.

2. Grit blasting prior to coating is not required.

3. Coating to be in the “as-sprayed” condition.

4. Overspray is permissible all around the inner platform side edges to a maximum of 0.060 in., Figure 3 refers.

CAUTION:

1.0 Remove overspray using RM-5, Dry Non-metallic Abrasive Blasting, as per reference (a), WP 017 01 to the following criteria:

c. Nozzle to work angle: 60 to 90 degrees

40 psi maximum.

CAUTION:

1.0 Coat to nominal dimension identified for the part with a tolerance of +/- 0.001”. Gage 100% of the vanes.

b. Use MSRR 9507/304(XJS) Tungsten Carbide/Cobalt Coating (LW-1N40), detonation flame deposit surfaces marked BB (inner platform side faces), Figure 2 refers, to produce 0.696/0.700 in. dimensions from datum A, Figure 2 refers.

NOTE:

1. Minimum coating thickness measured no less than 0.004 in.

2. Grit blasting prior to coating is not required.

3. Coating to be in the “as-sprayed” condition.

4. Overspray is permissible all around the inner platform side edges to a maximum of 0.060 in., Figure 3 refers.

CAUTION:

1.0 Remove overspray using RM-5, Dry Non-metallic Abrasive Blasting, as per reference (a), WP 017 01 to the following criteria:

c. Nozzle to work angle: 60 to 90 degrees

maximum.

1.0 Coat to nominal dimension identified for the part with a tolerance of +/- 0.001”. Gage 100% of the vanes.

c. Use MSRR 9507/304(XJS) Tungsten Carbide/Cobalt Coating (LW-1N40), detonation flame deposit surfaces marked BB (inner platform side faces), Figure 2 refers, to produce 0.316/0.320 in. dimensions from datum A, Figure 2 refers.

9.0 Visually inspect coating for integrity using IM-1, as per reference (a), WP 011 00, visual (white-light) inspection.

10.0 Dimensionally inspect detonation flame plating inner platform side faces, using inspection fixtures, G40415, and G40414, Figure 2 refers.

11.0 Vibro-Tumble to improve airfoil surface finish, to the following criteria:

a. Media, Vibratory: Z 1 ¾” Cones

b. Masking: None

c. Procedure: Local PAS

d. Compound: ALMCO 4320 Burnishing Compound or equivalent.

12.0 Line through existing part number and mark new part number, paragraph C refers, adjacent using the vibro-percussion engraving technique using MP2, as per reference (a), WP 008 00.

13.0 The contractor shall perform procedures IAW reference (c), WP 023 00 and WP 023 01 (inspection, removal and replacement of abradable coating) for stage 3 vanes. The following alternate processes may be substituted where applicable:

a. Alkaline Clean, J84AL, Omat 173J, as alternate to CM2, reference (a) refers.

b. Electrolytic Stripping per SPI: 5.2001, SPI 5.2008, and SPI 5.2009, as alternate to RM3, reference (a) refers.

c. Inspect per SPI 5.2002, as alternate to IM6, reference (a) refers.

d. Alkaline Clean Super Bee 300LF, Omat 1/24R, as alternate to CM2 and CM16, reference (a) refers.

e. Removal of abradable coating specified using CM11-H, reference (a), WP 009 11, to the following criteria:

1. Blast Media: Polyplus (MIL-P-85891, Type II)

2. Mesh Size: 12/20

3. Working Pressure:

a. Aspirated Cabinet; 60-80 psi

b. Pressure Cabinet: 30-35 psi

4. Nozzle Size: No. 5

5. Stand Off: 3 in. – 6 in.

f. The mineral spirit wipe prior to removal of abradable coating may be eliminated from the process if step 13.e. is used.

g. Masking is not required and may be eliminated from the process if step 13.e. is used.

14.0 Modify LPC Stage 3 vane side face, paragraph C refers.

a. Locate Vane to grinding fixture, F31687, paragraph D refers, and to a suitable machine. Set true and secure.

b. Locate Datum E, Figures 4, 5 and 6 refer. Finish machine, as necessary, the inner platform side face to produce 0.719/0.725 in. before flame plating dimension from Datum E, Figure 6 refers.

c. Remove burrs and sharp edges using hand tools as necessary, GRP1, GRP2, reference (a), WP014 00 refers.

15.0 Dimensionally inspect LPC Stage 3 vane inner platform side face using inspection fixture, G40413, paragraph D refers.

16.0 Modify LPC Stage 3 vane side face, paragraph C refers.

a. Locate Vane to grinding fixture, F31686, paragraph D refers, and to a suitable machine. Set true and secure.

b. Locate Datum E, Figures 4, 5 and 6 refer. Finish machine, as necessary, the inner platform side face to produce 0.326/0.332 in. before flame plating dimensions from Datum E, Figure 6 refers.

c. Remove burrs and sharp edges using hand tools as necessary, GRP1, GRP2, reference (a), WP014 00 refers.

17.0 Dimensionally inspect LPC Stage 3 vane inner platform side face using inspection fixture G40412, paragraph D refers.

18.0 Perform bead peen to accomplish airfoil surface restoration, and inner platform side face surfaces, marked BB, Figure 6 refers, all over as specified in reference (c), WP023 00, to the following criteria:

a. Blast Media: MIL-S-13165:165, Ceramic beads meeting SAE-J1830

b. Blasting intensity: Almen strip, Type N, arc height: 0.015 in. – 0.020 in.

c. Coverage: 200 percent.

19.0 Locally crack detect inner platform side faces using IM6 as per reference (a), WP 011 03.

20.0 The following operation is to be carried out by the Contractor

a. Mask off all over except surfaces marked BB (inner platform side faces), Figure 6 refers.

NOTE:

1. Minimum coating thickness measured no less than 0.004 in.

2. Grit blasting prior to coating is not required.

3. Coating to be in the “as-sprayed” condition.

4. Overspray is permissible all around the inner platform side edges to a maximum of 0.060 in., Figure 7 refers.

CAUTION:

1.0 Remove overspray using RM-5, Dry Non-metallic Abrasive Blasting, as per reference (a), WP 017 01 to the following criteria:

c. Nozzle to work angle: 60 to 90 degrees

40 psi maximum.

1.0 Coat to nominal dimension identified for the part with a tolerance of +/- 0.001”. Gage 100% of the vanes.

b. Use MSRR 9507/304(XJS) Tungsten Carbide/Cobalt Coating (LW- 1N40), detonation flame deposit surfaces marked BB (inner platform side faces), Figure 6 refers, to produce 0.729/0.733 in. dimensions from Datum E, Figure 6 refers.

NOTE:

1. Minimum coating thickness measured no less than 0.004 in.

2. Grit blasting prior to coating is not required.

3. Coating to be in the “as-sprayed” condition.

4. Overspray is permissible all around the inner platform side edges to a maximum of 0.060 in., Figure 7 refers.

CAUTION:

1.0 Remove overspray using RM-5, Dry Non-metallic Abrasive Blasting, as per reference (a), WP 017 01 to the following criteria:

c. Nozzle to work angle: 60 to 90 degrees

40 psi maximum.

1.0 Coat to nominal dimension identified for the part with a tolerance of +/- 0.001”. Gage 100% of the vanes.

c. Use MSRR 9507/304(XJS) Tungsten Carbide/Cobalt Coating (LW-1N40), detonation flame deposit surfaces marked BB (inner platform side faces), Figure 6 refers, to produce 0.336/0.340 in. dimensions from Datum E, Figure 6 refers.

21.0 Visually inspect coating for integrity using IM-1 as per reference (a), WP 011 00, visual (white-light) inspection.

22.0 Dimensionally inspect detonation flame plating inner platform side faces, using inspection fixture, G40413, and inspection fixture, G40412, Figure 6 refers, or by using locally manufactured equivalent fixtures.

23.0 Vibro-Tumble to improve airfoil surface finish, to the following criteria:

a. Media, Vibratory: Z 1 ¾” Cones

b. Masking: None

c. Procedure: Local PAS

d. Compound: ALMCO 4320 Burnishing Compound or equivalent.

24.0 Line through existing part number and mark new part number, paragraph C refers, adjacent using the vibro-percussion engraving technique MP2, as per reference (a), WP 008 00.

25.0 DELIVERABLES:

25.1 In order to keep the Government advised of any desired process and/or routing changes related to the Contractor repair process, the Contractor shall provide the Government a copy of the proposed process job router and/or changes to drawing (3AV35) S000041 for Government approval prior to change implementation.

26.0 POINT OF CONTACT: MRO Logistics Acquisition/Procurement Division, Services Branch.

a. Primary: Heather Unruh, heather.r.unruh.civ@us.navy.mil, 252-464-5535

b. Alternate: Aaron Avery, aaron.m.avery.civ@us.navy.mil, 252-464-5097

27.0 GENERAL INTENTION. The intent of this action is to establish a contract to provide for the modification LPC 2nd and 3rd Stage Vanes for the F402-RR-408 engine for the AV8 Aircraft. All supplies/services shall be provided/performed in accordance with the (SOW).

28.0 TYPE OF CONTRACT: This contract will be issued requirements contract in Accordance with FAR 52.216-21. The quantities listed in the schedule are estimates only listed in SOW Par. C and do not represent that the estimated quantities will be required or ordered. Funds shall be obligated by the issuing of Delivery Orders for precise quantities in accordance with FAR 52.216-21 “Requirements” (OCT 1995).

29.0 TERM OF CONTRACT: The contractor shall provide the items specified for a period of one (1) year beginning on the date of award with the provision for four additional option years.

30.0 PACKAGING AND MARKING

30.1 PREPARATION FOR DELIVERY

a) MARKING OF SHIPMENTS (COMMERCIALLY PACKAGED ITEMS)

i) Each shipping unit or crate shall be clearly, legibly, and permanently marked to show destination, contract number, gross weight, and number of units or crates in shipment. Marking shall be in accordance with ASTM-D-3951-82 “Standard Practice for Commercial Packaging”. Additional markings are stated below:

“NOT FOR OUTSIDE STORAGE”

“MARK WITH CONTRACT NUMBER”

30.2 PREPARATION FOR DELIVERY (COMMERCIALLY PACKAGED ITEMS)

a) All equipment shall be packed for shipment in a manner that will ensure acceptance by common carrier and safe delivery to the consignee. Containers and closures shall comply with Interstate Commerce Commission regulations, Uniform Freight Classification rules or regulations of other carriers as applicable to the mode of transportation.

b) Preservation, packaging, and packing shall be in accordance with ASTM-D-3951-90, Standard Practice for Commercial Packaging.

30.3 PROHIBITED PACKING MATERIALS

a) The use of asbestos, excelsior, newspaper or shredded paper (all types including waxed paper, computer paper, and similar hydroscopic or non-neutral material) is prohibited. In addition, loose fill polystyrene is prohibited for shipboard use.

30.4 PACKING LIST

a) In accordance with Military Standard 129, a packing list shall be included inside and attached to the outside of each box or container packed with unlike items where full description of the contents is not authorized or cannot be shown on the container. No packing list is required for containers having like items. The packing list will contain the following information:

i) Package number and set number (if any) of the container; TBD

ii) A list of contents including quantity by item, item description, stock number or part number, type and size, condition of material, unit of issue if other than each, and reference publications and dates of issue when applicable; and

iii) Other information in sufficient detail so that the article can be replaced.

30.5 HAZARDOUS MATERIALS

a) Packaging, packing, marking and labeling of hazardous materials to be shipped by any mode or combination of transportation modes shall be prepared (properly classed, described, packaged, marked, labeled, transport vehicle placarded, etc.) for shipment in accordance with MIL-STD 129 and all applicable government and carrier regulations in effect at time of shipment.

i) TYPE OF SHIPMENT APPLICABLE REGULATION

ii) 1. Domestic A

iii) 2. Domestic Air Commercial A, B, C

iv) 3. Domestic Air Military A, F

v) 4. Export Surface A, E, G

vi) 5. Export Air Commercial A, D, G

vii) 6. Export Air Military (MAC) F, G

30.6 LIST OF REGULATIONS

a) Code of Federal Regulations Title: 49 Transportation Parts 100-199

b) Official Air Transport Restricted Articles Tariff No. 6-D C.A.B. 82

c) Official Air Transport Restricted Articles Circular No. 6-D

d) International Air Transport Association Restricted Articles Regulation

e) International Maritime Dangerous Goods Code

f) Air Force Regulation 71-4 Preparation of Hazardous Materials for Military Air Shipment Export shipments are also subject to the domestic regulations indicated to the port of embarkation.

31.0 DELIVERY NOTE

31.1 PLACE OF DELIVERY (DESTINATION): All supplies, materials, and documentation to be furnished hereunder shall be delivered, FOB Destination, all transportation charges paid by the contractor, to:

Fleet Readiness Center DLA Receiving Officer Beachey Road Building 148, Bay C Cherry Point, NC 28533

31.2 REQUIRED DELIVERY DATES

a. Pursuant to the requirements of each order placed, the vanes shall be shipped at the Government's expense, FOB to the contractor's plant. The contractor shall inspect/modify the vanes in accordance with Statement of Work and return the modified vanes within forty-five (45) business days after receipt. The Contractor shall ship each CLIN item under this order via ground – best method, FOB Destination. The modified vanes may be returned by Federal Express / Overnight Shipment if a determination of urgency is identified. The Contracting Officer will modify the Delivery Order to allow for Federal Express, when expedited shipment is requested. The shipping charges for expedited delivery shall be prepaid by the contractor and added as a separate line item to the invoice. When the needs of the Government permit, orders may provide for a longer delivery schedule. Partial deliveries are acceptable.

b. All requirements for delivery will be in accordance with the Delivery Information provided within each Delivery Order.

c. Documentation: All documentation shall be delivered in accordance with the requirements of the Statement of Work.

32.0 MONTHLY STATUS REPORT (MSR) (CDRL)

32.1 MSR. The Contractor shall prepare a monthly status report to the FRC East, DLA Aviation coordinator for the F402 program that includes the delivery order numbers for each active task order that documents the Estimated Completion Date (ECD) of all applicable items.