DRAFT Source Sought_ SOW.docx

Statement of Work (SOW) For LM2500 Power Turbine Blade and Vane Inspection and Repair

1.0 INTRODUCTION

1.0.1 The Naval Surface Warfare Center Philadelphia Division (NSWCPD) is a Department of Defense entity responsible for research and development, test and evaluation, engineering and fleet support organization for the Navy’s ships, submarines, military watercraft and unmanned vehicles. This requirement is for NSWCPD Code 424, which is responsible for In-Service Engineering Agent (ISEA) support for the US Navy fleet.

1.0.2 This contract is for non-personal services. It does not create employment rights with the U.S. Government whether actual, inherent, or implied

1.0.3 Government/Contractor Relationship

1.0.3.1 The services to be delivered under this Contract are non-personal services and the parties recognize and agree that no employer-employee relationship exists or will exist under the Contract between the Government and the Contractor's personnel. Therefore, it is in the best interest of the Government to provide both parties a full understanding of their respective obligations.

1.0.3.2 The Contractor employees shall identify themselves as Contractor personnel by introducing themselves or being introduced as Contractor personnel and displaying distinguishable badges or other visible identification for meetings with Government personnel. In addition, Contractor personnel shall appropriately identify themselves as Contractor employees in telephone conversations and in formal and informal written correspondence.

1.0.3.3 Contractor personnel under this Contract shall not engage in any of the inherently Governmental functions listed at FAR Subpart 7.5 or DFARS Subpart 207.5.

1.0.4 Employee Relationship:

1.0.4.1 The services to be performed under this Contract do not require the Contractor or its personnel to exercise personal judgment and discretion on behalf of the Government. Rather the Contractor's personnel will act and exercise personal judgment and discretion on behalf of the Contractor.

1.0.4.2 Rules, regulations, directives, and requirements that are issued by the U. S. Navy and NSWCPD under its responsibility for good order, administration, and security are applicable to all personnel who enter a Government installation or who travel on Government transportation. This is not to be construed or interpreted to establish any degree of Government control that is inconsistent with a non-personal services contract.

1.0.4.3 Inapplicability of Employee Benefits: This Contract does not create an employer-employee relationship. Accordingly, entitlements and benefits applicable to such relationships do not apply.

1.0.4.4 It is the Contractor's, as well as the Government's, responsibility to monitor Contract activities and notify the Contracting Officer if the Contractor believes that the intent of this Section has been or may be violated.

1.0.4.4.1 The Contractor shall notify the Contracting Officer in writing via letter or email within three (3) calendar days from the date of any incident that the Contractor considers to constitute a violation of this Section. The notice should include the date, nature, and circumstances of the conduct; the name, function, and activity of each Government employee or Contractor official or employee involved or knowledgeable about such conduct; identify any documents or substance of any oral communication involved in the conduct; and the Contractor's estimated date when, absent a response, cost, schedule or performance will be impacted.

1.0.4.4.2 The Contracting Officer will, within five (5) calendar days after receipt of notice, respond to the notice in writing. In responding, the Contracting Officer will either:

1.1 BACKGROUND

The Surface Combatant/Gas Turbine Engineering Branch (Code 424) of the Naval Surface Warfare Center, Philadelphia Division (NSWCPD) provides guidance for the development, acquisition, modernization, and maintenance of all gas turbine systems to meet Navy war fighting requirements. NSWCPD Code 424 has begun to utilize repair activities outside of repair depots in an effort to reduce the scrap rates and overhaul costs of U.S. Navy LM2500 engines. By establishing a rotatable pool of ready-for-issue (RFI) power turbine blades and vanes, overhaul depots can reduce the repair turnaround time (RTAT) and US Navy can continue to maintain its fleet sparing requirements.

1.2 SCOPE OF WORK

The contractor shall provide Naval Surface Warfare Center Philadelphia (NSWCPD) with repaired components (“A” condition) to support the LM2500 Marine Gas Turbine Engine Repair Program. All non-repairable airfoils will be separated out and returned to NSWCPD as specified under the requirements of this document. NSWCPD will ship “F” condition components to the contractor at their request. The number of airfoils shipped will be documented and will not exceed 1,188 airfoils per container which, under this work scope, is one complete engine set. Note: vane segments are comprised of either 2-vane segments or 6-vane segments depending on the part number.

This work scope identifies the general requirements for the refurbishment of LM2500 power turbine airfoils. Items provided under this contract are used LM2500 gas turbine engine power turbine airfoils. They may or may not be repairable for future use in Navy gas turbine engines.

Under this contract, an 'A' condition component is an airfoil that has undergone the complete overhaul process and restored to the airfoil part number’s original OEM production standards each complete with a certificate of conformance and considered Ready-For-Issue (RFI). An "F' condition component is a component that is not Ready-For-Issue (nRFI) and requires overhaul to return the component to "A" condition. Note: Overhaul is defined as a thorough examination, with repairs or changes as necessary.

2.0 APPLICABLE DOCUMENTS

While every effort has been made to ensure the completeness of this work scope, document users are cautioned that they shall meet all specified requirements cited in Section 3 of this specification, in addition to Section 9, Government Furnished Information.

The contractor shall restore ‘F’ condition airfoils to ‘A’ condition airfoils through the overhaul process. If the contractor possesses the capability to upgrade the airfoil to its latest configuration based upon U.S. Navy part number requirements that is also acceptable.

Table 1: Government Furnished Material for Repair LM2500 Low Pressure Turbine Blades & Vanes

Projected Airfoil Engine Sets Per Year

9663M11P06

9663M11P12

9663M11P17

L47571P01

L21492P04

LM2500

Low Pressure Turbine Blades

9663M12P04

L47572P01

L21493P04

L47573P01

9663M14P08

9663M14P21

L47574P01

Blade, LPT Stage 5 9102M35P01

9102M35P07

9102M35P08

L47575P01

L47576P01

Projected Airfoil Engine Sets Per Year

LM2500

Low Pressure Turbine Vanes

Vane, LPT Stage 2 L21752G01

L21752G04

L38152G01

L21752G02

L21752G05

L38152G02

L21752G03

L21752G06

L38152G03

L38152G04

L38152G05

L38152G06

Vane, LPT Stage 3 L21753P01

L21753P03

L21753P12

L21753G01

L21753G02

L21753G05

L21753P02

L21753P04

L21753P13

Vane, LPT Stage 4

9663M04P02

9663M04P04

4013009914P01

Vane, LPT Stage 5

9663M05P05

Vane, LPT Stage 6

9663M06P02

9663M06P04

L31846G04

4013009916P01

*All airfoils furnished for repair shall, at a minimum, be restored to its original OEM production standards under the requirements of this specification. Airfoil quantities for LPT vanes do not include stage 1 airfoils.

2.1 Technical Manuals

2.1.1 NAVSEA Technical Manuals

The contractor shall, at a minimum, restore airfoils to their original OEM production standards under the requirements of this specification where economically feasible. Upgrading the component to its latest configuration based upon U.S. Navy part number requirements is also acceptable.

The contractor may use the below NAVSEA Technical Manual number (latest revision in effect at the start of the work) to determine the latest configuration if needed.

NAVSEA Technical Manuals:

(1) S9234-AD-MMO-070

NSWCPD will not provide any repair standards through the use of NAVSEA approved overhaul technical manuals to assist in the repair of these components.

3.0. REQUIREMENTS

The contractor shall perform an incoming inspection of all Navy provided LM2500 airfoils for serviceability and submit CDRL A001 - GFP Baseline and Initial Inspection Report, CDRL A002 - GFP Monthly Inventory Report, and CDRL A004 - Government Furnished Property Final Report. The offerors shall use industry best practices to assess the parts for repairability. The service criteria to be utilized to evaluate the parts must be shared with the Navy. The parts can be cleaned and inspected with special equipment as the vendor sees fit to perform this analysis. All Navy parts shall be tracked with individual routing documents.

The contractor shall possess all supplies and materials necessary to accomplish the refurbishment of LM2500 power turbine airfoils. The contractor shall also own or have under contract the necessary tools and equipment required to apply platinum aluminide or similar aluminide coating to the required airfoils following the refurbishment process.

The US Navy will not provide, nor be responsible for, any special support equipment, tooling, machinery, or materials used for the refurbishment of US Navy LM2500 airfoils.

3.1 Blade Overhaul

3.1.1 Inspection

The contractor shall inspect, repair, test, preserve, package, document, mark and prepare for shipment all LM2500 PTA ‘A’ and ‘F’ condition material in accordance with the contract requirements.

Upon receipt of “F” condition material, the contractor shall inspect the material in accordance with the contract repair requirements and submit CDRL A001 – GFP Baseline and Initial Inspection Report, CDRL A002 - GFP Monthly Inventory Report, and CDRL A004 - Government Furnished Property Final Report. At a minimum, the incoming inspection report shall contain:

(1) Nomenclature/Part Number/Serial Number

(2) Mode of Failure

(3) Digital Photograph of Damage

(4) Inspection Methods

(5) Inspection Data and Damage Results

(6) Inspection Equipment Report Including Applicable Calibration Information

(7) Engineering Comments

(8) Qualifying/Non-Qualifying Status based on Repair Criteria

Blade inspection shall include:

· All areas (except shroud seal serrations) for cracks

· Leading and trailing edges (except areas X and Y) for nicks, scratches, and dents

· Concave and Convex surfaces (except areas X and Y) for nicks, scratches, and dents

· Leading and trailing edges (in areas X and Y) including root radius for nicks, dents, and scratches

· Concave and convex surfaces (in areas X and Y) including root radius for nicks, dents, and scratches

· Airfoil for surface roughness and missing coating (stages 1 & 2)

· Top Surface of blade platform (not including blade root radius) for nicks, scratches, dents, front and/or rear edge bent, and missing coating (stages 1 & 2)

· Blade shank (including mating surface) for nicks, scratches, dents, and front and/or rear skirt section bent

· Dovetail serrations for nicks, scratches, dents, galling, or fretting

· Shroud Seal Serrations for wear on OD, turned metal, and cracks

· Shroud Locks for wear and separation of hardcoat shroud

· Shroud Trailing Edge for nicks, dents, scores, pitting, and surface wear

· Shroud Leading Edge for nicks, dents, scores, and pitting

· Blade pre-twist angle

Figure 1: Power Turbine Rotor Blades If the blade has been damaged to the point that it cannot meet the requirements to get it from “F” condition to “A” condition under the requirements of this work scope, the component shall be considered beyond economic repair (BER) and labeled as “F” condition. Those parts deemed non-repairable under this work scope should be segregated for return to the Navy without further processing. Each part evaluated as non-repairable at this phase of incoming inspection should be tagged with a brief explanation of the observations or findings which rendered the part non-repairable. The tag with explanation should be affixed to the non-repairable part. No special handling aside from the tagging is required for parts which are considered non-repairable. Non-repairable parts shall be stored for bulk shipment back to the Navy on a quarterly basis, coinciding with the submission of the contractor Quarterly BER Status Report in accordance with CDRL A005 – Quarterly Beyond Economic Repair (BER) Status Report, but cannot be scrapped locally.

Any inspections performed on an airfoil shall be documented with shop routing documents which include results of tests performed. The routing documents must reside with the individual components through the evaluation process.

3.1.2 Repair

All dimensional tolerances of the original OEM production standards for the part number must be met after repair. If part number is being upgraded to the latest US Navy part configuration then the OEM production standards for the upgraded part number must be met.

All repair work performed under this work scope shall be for articles to be delivered as ‘A’ condition. All parts shall be cleaned in accordance with US Navy approved standard commercial procedures. The repaired LM2500 power turbine blades shall be free of all corrosion when delivered to the US Navy.

Repairs under this contract are limited to as necessary minor repairs which include blending, twist repair, root shot peening, and applying platinum aluminide or similar aluminide coating where necessary (stages 1&2) in order to return the blade to acceptable OEM production standards. All blades that require higher level repairs such as z-notch and seal repairs are to be considered beyond economic repair (BER) under this work scope and returned to NSWCPD in accordance with the requirements of this document.

Stage 1, 2, and 3 (if necessary) blades shall be stripped, cleaned, and coated in accordance with sections 3.1.2.1 and 3.1.2.2 of this work scope. Stages 3, 4, 5, and 6 blades shall be cleaned but not coated after repair.

No blending of airfoils or blade platforms is allowed on coated stage 1 and 2 blades. Only blend stage 3, 4, 5, and 6 non-coated blades. Damage shall be removed by use of a power tool or by hand, using smooth mill file or emery cloth, depending on how much material is to be removed. When removing damage by power tool, finish blend to approximately 1/64 inch from final contour. Following use of power tool, blend with smooth mill file. Remove only enough material to eliminate damaged area. After blending, use fine emery cloth or abrasive stone in longitudinal direction (parallel to airfoil length) to remove all tool marks and polish surface to original contour and to finish of airfoil and adjacent platform surface. When blending out damage on stages 3, 4, 5, and 6 power turbine blade leading and trailing edges the length of blend shall be a minimum of 6 times the depth of damage. If two or more blend areas overlap, remove protruding metal at overlap to prevent stress riser. Do not remove any material from airfoil at blade tip or platform. Airfoil leading and trailing edge in repaired area shall be contoured and polished to original finish in longitudinal direction (parallel to blade length).

Shot peening shall be performed in accordance with AMS 2430 and MIL-S-13165. Part to be shot peened shall be repaired, heat-treated, machined, ground, polished, burrs and sharp edges removed as necessary before shot peening. Part shall be within required dimensional limits and surface finish, unless otherwise specified. When required, magnetic particle or fluorescent-penetrant inspection must be accomplished before peening. Clean part of grease, oil and dirt. Mask part at designated areas with cloth-back tape when protection from peening is required. See specific shot peening procedure for areas to be masked. Record part number, serial number, location of each, and method of application, so that part may be re-marked after peening.

If the cost of repair per blade amounts to more than 75% of the cost of a new blade of the part number being repaired, the airfoil is considered to be beyond economic repair and labeled as BER. The blade should then be returned to NSWCPD in accordance with the requirements of this document.

For all orders issued under this contract, the contractor shall package completed repairs by stages before shipping back to NSWCPD (i.e. stage 1, stage 2, stage 3, etc.). Note: completed repairs are not required to be in the form of kits or a specific quantity before being shipped back to NSWCPD. It is recommended that repaired blades be shipped with repaired vanes of the same task order once the task order has been completed to reduce shipping costs. Note: the quantity of blades being shipped may be affected by fallout.

Orders shipped to contractor by the Government may have varying part numbers, and the number of airfoils per shipped container will not exceed 1,188 airfoils. Components and quantities that comprise each stage are identified in Table 1.

Upon completion of each repair, the blade shall be stamped with the part number in accordance with US Navy approved standard commercial practices.

All repairs shall be completed within 100 days or less of Task Order issuance. Contractor shall provide a completion report in accordance with CDRL A003 – Repair Completion Report.

If, after contract award, the contractor proposes to use repair procedures which are not specifically allowable under the current Statement of Work or have not been evaluated by Navy subject matter experts to complete the repair, the contractor must receive technical approval in writing from NSWCPD Code 424 for use of any alternate repair procedures in accordance with section 3.4 of this document. Deviations without written approval are not authorized.

3.1.2.1 Cleaning and Stripping of Airfoil Coating

Some incoming airfoils will be coated with a special aluminide coating which will require stripping/removal. The contractor shall utilize its own industry best practices to clean and strip coating from the airfoils. The stripping practice shall be optimized to remove airfoil coatings while preserving the parent metal of the component part.

The intent of the coating is to provide protection of the airfoil during service operation of the engine. The coatings may be removed via an abrasive waterjet (AWJ), solution bathes, or physical processes including grit blast to expose the parent metal of the airfoil. Residual coating should not be present at the completion of the cleaning and stripping process. The Navy is intentionally not selecting the procedure or chemicals to be used so that industry best practices can be utilized by the contractor. The vendor shall use the process which is most effective at removing the coating while attempting to minimize the amount of parent metal lost during the stripping process. If required, the vendor may use different processes depending upon coating type.

· Observe correct paperwork is with part. Be certain previous operations have been signed off and part count is correct.

· If controls are not followed or acceptable time in the strip solution bath is exceeded, unacceptable intergranular attack (IGA) may occur

· The temperature of the stripping solution bath must not exceed a maximum of 90°F or unacceptable IGA will occur

· Stripping solution qualification: the stripping solution must be qualified by processing a specimen, for metallographic examination, through the stripping cycle prior to stripping the initial lot of parts, such as when a new solution is mixed or a solution is replenished

Following the stripping of the coating, the vendor shall verify the candidate airfoil for serviceability. It is possible that parts inspected after the cleaning phase may reveal conditions which render its repairability impractical. Those parts found unserviceable will be considered BER and handled as such.

Blades are to be processed through the stripping procedure in lots. Maximum of 150 pieces per lot, including the samples that will be used for process control. One sample will be used to evaluate hardware to the limits specified in the repair procedure. Qualification of the stripping solution is required as specified prior to stripping the initial lot of parts.

Airfoils repaired under this contract shall receive full repairs only. Incoming airfoils may have gas path deposits on the airfoil surface along with possible nicks and dents. Partial repairs which include not stripping any coatings from the airfoil is not permitted.

3.1.2.2 Blade Coating Requirements

The vendor shall ensure no line of sight application issues will impact blade coating uniformity. The specified airfoils will be coated (airfoil and platform surfaces) with platinum aluminide or similar coating, nominal 0.002-0.003” thickness. All original OEM production standard dimensional tolerances must be met after coating.

Notwithstanding anything to the contrary contained in the contract repair requirements, the contractor shall coat the blades as follows:

a. All serviceable stage 1 and stage 2 LPT blades shall be provided with aluminide coating.

b. All serviceable stages 3 through 6 LPT blades shall be provided with no coating.

3.1.3 Technical Deviations Approval

Deviations from the latest revisions of the repair requirements, such as waivers, engineering change proposals, material substitutions, engineering directives or alternate overhaul methods, not specifically stated in approved repair procedures shall only be permitted after processing deviations and obtaining written approval from NSWCPD Code 424 and the Contracting Officer. See request for variance (DI-SESS-80640E) and request for waiver (DI- SESS-81732)

All processes, procedures, inspection criteria, and components used in the repair of US Navy LM2500 LPT blades shall be approved by NSWCPD Code 424 and the Contracting Officer in writing for use or implementation in the blade repair.

The US Navy upon written request will evaluate additional procedures and components on a case-by-case basis, but are not approved for use without written authorization from NSWCPD Code 424.

3.1.4 Testing Requirements

The contractor shall utilize industry best practices to return the LM2500 power turbine component to new part dimensional measurements. After coating and/or repair of the blade is completed, the contractor shall ensure the original OEM production standard dimensional tolerances are met. All airfoil and dovetail dimensional tolerances must be met. Only hand polishing permitted on dovetails following finish grinding. The contractor shall provide a repair certification letter stating that the individual component meets the OEM production standards to NSWCPD 424 upon completion of each component repair.

The vendor shall complete the inspection and refurbishment of blades within 100 Calendar days after receipt of the GFM. If the vendor has a facility calibration or maintenance related shutdown which will impact its ability to complete repairs within the requisite timeframe, the vendor must contact the Navy TPOC to explain the service outage and its planned completion date.

3.1.5 Marking, Packaging, and Shipping

The contractor will be responsible for all shipping requirements. The contractor shall have the ‘F’ condition components shipped from NSWCPD to the contractor’s facility. Upon completion of the repair, the contractor shall hermetically seal the ‘A’ condition components for preservation and ship them back to NSWCPD with individual component repair certification letters.

In addition to part number (PN) markings contained herein, repaired blades shall be marked, in accordance with standard commercial practice, with a marking to indicate order number and repair date. This marking can be discussed after award of contract.

If repairs are completed outside the continental United States (OCONUS), the vendor must facilitate returning the Navy parts back to a location within the United States such that any customs fees and requirements are not borne by the Navy or NSWC. OCONUS vendors must ensure any customs and transportation costs are included in their repair pricing. The Navy will not be responsible for customs costs or logistics related to transporting GFM parts back to the Navy.

3.2 Vane Overhaul

3.2.1 Inspection

The contractor shall inspect, repair, test, preserve, package, document, mark and prepare for shipment all LM2500 PTA ‘A’ and ‘F’ condition material in accordance with this specification.

Upon receipt of ‘F’ condition material, the contractor shall inspect the material in accordance with the contract repair requirements and submit CDRL A001 – GFP Baseline and Initial Inspection Report, CDRL A002 - GFP Monthly Inventory Report, and CDRL A004 - Government Furnished Property Final Report. At a minimum, the incoming inspection report shall contain:

(1) Nomenclature/Part Number/Serial Number

(2) Mode of Failure

(3) Digital Photograph of Damage

(4) Inspection Methods

(5) Inspection Data and Damage Results

(6) Inspection Equipment Report Including Applicable Calibration Information

(7) Engineering Comments

(8) Qualifying/Non-Qualifying Status based on Repair Criteria

Nozzle inspection shall include:

· Outer and Inner Platforms for cracks and missing coating (stage 2)

· Airfoil leading and trailing edges for cracks, nicks, scores, dents, and surface roughness

· Airfoil leading and trailing edges for missing coating (stage 2) and bowed or bent trailing edge

· Airfoil surfaces other than edges for cracks, nicks, scratches, dents, surface roughness, missing coating (stage 2)

· Inner Tang for cracks, nicks, dents, scratches, wear, fretting, corrosion, bent and missing tang (stage 2-6 only)

· Outer Front Rail for cracks, slot wear (Dim X), and exterior damage (stages 2-6 only)

· Inner Front Rail for cracks (stages 2-6 only)

· Outer Rear Rail for cracks on web portion, cracks on outer flange portion, and wear or damage on outer flange portion

· Outer Platform Gussets for cracks (stages 2-6 only)

· Seal Strip Retainers for missing, cracked, and bent retainers, seal strip slot breakthrough at forward retainer radii (stage 1 only), cracks in retainer wall (stage 2 only), broken out area in retainer wall (stage 2)

· Airfoil internal and external surface for corrosion products – deposits/buildup

Figure 2: Power Turbine Nozzles, All Stages If the vane has been damaged to the point that it cannot meet the requirements to get it from ‘F’ condition to an ‘A’ condition, the component shall be considered beyond economic repair (BER) and labeled as ‘F’ condition. Those parts deemed non-repairable under this work scope should be segregated for return to the Navy without further processing. Each part evaluated as non-repairable at this phase of incoming inspection should be tagged with a brief explanation of the observations or findings which rendered the parts non-repairable. The tag with explanation should be affixed to the non-repairable part. No special handling aside from the tagging is required for parts which are considered non-repairable. Non-repairable parts shall be stored for bulk shipment back to the Navy on a quarterly basis, coinciding with the submission of the contractor Quarterly BER Status Report in accordance with CDRL A005 – Quarterly Beyond Economic Repair (BER) Status Report, but cannot be scrapped locally.

Any inspections performed on a vane should be documented with shop routing documents which include results of tests performed. The routing documents must reside with the individual vane through the evaluation process.

3.2.2 Repair

All repair work performed under this specification shall be for articles to be delivered as ‘A’ condition. All parts shall be cleaned in accordance with US Navy approved standard commercial procedures. The repaired LM2500 power turbine vanes shall be free of all corrosion when delivered to the US Navy.

Repairs under this contract are limited to as necessary minor repairs which include blending and applying platinum aluminide or similar aluminide coating where necessary (stage 2) in order to return the vane to acceptable OEM production standards. All vanes that require higher level repairs are to be considered beyond economic repair (BER) and returned to NSWCPD in accordance with the requirements of this work scope.

Stage 2 and 3 (if necessary) vanes shall be cleaned, stripped, and coated in accordance with sections 3.2.2.1 and 3.2.2.2 of this work scope. Stages 3, 4, 5, and 6 vanes shall cleaned but not coated.

No blending of airfoils or airfoil surfaces is allowed on coated stage 2 nozzles. Only blend stage 3, 4, 5, and 6 non-coated airfoils. Damage shall be removed by use of a power tool or by hand, using smooth mill file or emery cloth, depending on how much material is to be removed. When removing damage by power tool, finish blend to approximately 1/64 inch from final contour. Following use of power tool, blend with smooth mill file. Remove only enough material to eliminate damaged area. After blending, use fine emery cloth or abrasive stone to remove all tool marks and polish surface as close as practical to original contour and to finish of airfoil and adjacent platform surface. When blending out damage on stages 3, 4, 5, and 6 power turbine blade leading and trailing edges the length of blend shall be a minimum of twice the depth of damage. Obtain a smooth radius, 1/8 inch minimum, at bottom and corner of blends. If two or more blend areas overlap, remove protruding metal at overlap to prevent stress riser.

If the cost of repair per vane segment amounts to more than 75% of the cost of the new part number being repaired, the vane is considered to be beyond economic repair and shall be labeled BER and treated as such. The vane should then be returned to NSWCPD in accordance with the requirements of this document.

All dimensional tolerances of the original part number OEM production standards must be met after repair. When necessary, part numbers that reflect a 2-vane segment for stages 4, 5, and 6 will be required to be upgraded to the latest 6-vane segment configuration. Part numbers that are required to be upgraded do not fall in the minor repair category, as stated above, because they require a larger work scope. These vane segment upgrades will require services such as welding, machining, blending, heat treatment, and specific types of inspections to complete. Vanes that are 2-vane segments will not be repaired without being upgraded to the current 6-vane segment configuration. The contractor shall use any available 2-segment vanes available under the task order to create as many 6-vane segments as possible.

For all orders issued under this contract, the contractor shall package completed repairs by stage before shipping back to NSWCPD (i.e. stage 2, stage 3, stage 4, etc.). Note: completed repairs do not require to be in the form of kits or a specific quantity before being shipped back to NSWCPD. It is recommended that repaired vanes be shipped along with repaired blades of the same task order once the task order has been completed to reduce shipping costs. Note: the quantity of vane segments being shipped may be affected by fallout.

Orders shipped to contractor by the Government may have varying part numbers, but the number of airfoils per container will not exceed 1,188 airfoils. Note: vanes may consist of two (2) airfoils or six (6) airfoils per segment depending on the part number. Components and quantities that comprise each stage are identified in Table 1. Stage 1 vanes are not included in this work scope.

All repairs shall be completed within 100 days or less of Task Order issuance. Contractor shall provide are pair completion report in accordance with CDRL A003 – Repair Completion Report.

If, after contract award, the contractor proposes to use repair procedures which are not specifically allowable under the current Statement of Work or have not been evaluated by Navy subject matter experts to complete the repair, the contractor must receive technical approval in writing from NSWCPD Code 424for use of any alternate repair procedures in accordance with section 3.4 of this document. Deviations without written approval are not authorized.

3.2.2.1 Cleaning and Stripping of Airfoil Coating

Some incoming airfoils will be coated with a special aluminide coating which will require stripping/removal. The contractor shall utilize its own industry best practices to clean and strip coating from the vanes. The stripping practice shall be optimized to remove the coating while preserving the parent metal of the part.

The intent of the coating is to provide protection of the airfoil during service operation of the engine. The coatings may be removed via an abrasive waterjet (AWJ), solution bathes, or physical processes including grit blast to expose the parent metal of the airfoil. Residual coating should not be present at the completion of the cleaning and stripping process. The Navy is intentionally not selecting the procedure or chemicals to be used so that industry best practices can be utilized by the contractor. The vendor shall use the process which is most effective at removing the coating while attempting to minimize the amount of parent metal lost during the stripping process. If required, the vendor may use different processes depending upon coating type.

· Observe correct paperwork is with part. Be certain previous operations have been signed off and part count is correct.

· If controls are not followed or acceptable time in the strip solution bath is exceeded, unacceptable IGA may occur

· The temperature of the stripping solution bath must not exceed a maximum of 90°F or unacceptable IGA will occur

· The stripping solution must be qualified by processing a specimen, for metallographic examination, through the stripping cycle prior to stripping the initial lot of parts, such as when a new solution is mixed or a solution is replenished Following the stripping of the coating, the vendor shall re-inspect the candidate GFM for serviceability. It is possible that parts inspected after the cleaning phase may reveal conditions which render its reparability impractical. Those parts found unserviceable will be considered beyond economic repair (BER) and handled as such.

Airfoils repaired under this contract shall receive full repairs only. Incoming airfoils may have gas path deposits of the airfoil surface along with possible nicks and dents. Partial repairs which include not stripping any coatings from the airfoil are not permitted.

3.2.2.2 Vane Coating Requirements

The vendor shall ensure no line of sight application issues will impact blade coating uniformity. The specified airfoils will be coated (airfoil and platform surfaces) with platinum aluminide or similar aluminide coating, nominal 0.002-0.003” thickness. All original OEM production standard dimensional tolerances must be met after coating.

Notwithstanding anything to the contrary contained in the contract repair requirements, the contractor shall coat the vanes as follows:

a. All serviceable stage 2 vanes (nozzles) shall be provided with aluminide coating. Coating shall not exceed 0.0045” thickness.

b. All serviceable stages 3 through 6 vanes (nozzles) shall be provided with no coating.

3.2.3 Technical Deviations Approval

Deviations from the latest revisions of the repair requirements, such as waivers, engineering change proposals, material substitutions, engineering directives or alternate overhaul methods, not specifically stated in these manuals shall only be permitted after processing deviations and obtaining written approval from NSWCPD Code 424 and the Contracting Officer. See request for variance (DI-SESS-80640E) and request for waiver (DI-SESS-81732).

All processes, procedures, inspection criteria, and components used in the repair of US Navy LM2500 LPT vanes shall be approved by NSWCPD Code 424 and the Contracting Officer in writing for use or implementation in the vane repair.

The US Navy upon written request will evaluate additional procedures and on a case-by-case basis, but are not approved for use without written authorization from NSWCPD Code 424

3.2.4 Testing Requirements

The contractor shall utilize industry best practices to return the LM2500 power turbine vanes to new part dimensional measurements. After coating and/or repair of the vane (nozzle) is completed, the contractor shall ensure all dimensional tolerances are met in accordance with the part number original OEM production standards. The contractor shall provide a repair certification letter stating that the individual component meets the OEM production standards to NSWCPD 424 upon completion of each vane repair.

The vendor shall complete the inspection and refurbishment of Navy GFM vanes within 100 Calendar days after receipt of the GFM. If the vendor has a facility calibration or maintenance related shutdown which will impact its ability to complete repairs within the requisite timeframe, the vendor must contact the Navy TPOC to explain the service outage and its planned completion date.

3.2.5 Marking, Packaging, and Shipping

The contractor will be responsible for all shipping requirements. The contractor shall have the ‘F’ condition components shipped from NSWCPD to the contractor’s facility. Upon completion of the repair, the contractor shall hermetically seal the ‘A’ condition components for preservation and ship them back to NSWCPD along with individual component certification letters.

In addition to part number (PN) markings contained herein, repaired vanes shall be marked, in accordance with standard commercial practice, with a marking to indicate order number and repair date. This marking can be discussed after award of contract.

If repairs are completed outside the continental United States (OCONUS), the vendor must facilitate returning the Navy parts back to a location within the United States such that any customs fees and requirements are not borne by the Navy or NSWC. OCONUS vendors must ensure any customs and transportation costs are included in their repair pricing. The Navy will not be responsible for customs costs or logistics related to transporting GFM parts back to the Navy.

3.3 Manufacturing Phase-Out or Discontinuation of Production, Diminishing Sources, and Obsolete Materials or Components

3.3.1 The contractor shall notify the contracting officer immediately upon determining the unavailability of obsolete materials or components. The contractor may recommend a solution to include the impact on the contract price and delivery. The contractor shall not initiate any item redesign or incur any additional costs without the express, written authorization of the contracting officer.

4.0 DATA REQUIREMENTS

4.2.2 The report should address the following elements: Delivery Order Number, Item description, Part Number, Item Quantity, NSN, location(s), estimating shipping date, and comments such as needed assets and/or relevant information or projections affecting the shipment of completed components.

4.2.3 The contractor shall submit an electronic status report immediately upon determination by the contractor of a delay in delivery and at a minimum, submit a monthly status report to NSWCPD TPOC and contracting officer in accordance with CDRL A002.

4.3.2 The CDRL shall be delivered electronically unless otherwise stated.

4.3.3 Within twenty (20) days of completion of repairs, the contractor shall provide a repair completion report in the contractor’s format in accordance with CDRL A003. This report shall incorporate CDRL A001 and include the following:

5.0 SECURITY REQUIREMENTS

5.1 SECURITY TRAINING

Not applicable.

5.2 ON SITE WORK.

Not applicable.

5.3 OPERATIONS SECURITY (OPSEC)

5.3.1 The Contractor shall protect critical information associated with this contract to prevent unauthorized disclosure. The NSWC Philadelphia Division's (NSWCPD) Critical Information List (CIL)/ CIIL (Critical Indicators and information list) will be provided on site, if warranted. Performance under this contract requires the contractor to adhere to OPSEC requirements. The Contractor may not impose OPSEC requirements on its subcontractors unless NSWCPD approves the OPSEC requirements. During the period of this contract, the Contractor may be exposed to, use, or produce, NSWCPD Critical Information (CI) and/or observables and indicators which may lead to discovery of CI. NSWCPD’s CI will not be distributed to unauthorized third parties, including foreign governments, or companies under Foreign Ownership, Control, or Influence (FOCI) unless such FOCI has been appropriately mitigated through measures approved by the Defense Counterintelligence and Security Agency. Questions concerning these requirements shall be directed to the PCO.

5.3.2 CUI correspondence transmitted internally on the contractor's unclassified networks or information systems, and externally, shall be protected per NIST SP-800-171, Protecting Controlled Unclassified Information (CUI) in Non-federal Systems and Organizations.

Assembled large components/systems being transported to and from testing areas, other production or government facilities (whether or not on public roadways) shall be in an enclosed van trailer or covered flatbed trailer. Component/System outside storage, staging, and test areas shall be shielded/obscured from public view wherever physically possible.

5.3.3 NSWCPD’s CI shall not be publicized in corporate wide newsletters, trade magazines, displays, intranet pages or public facing websites. Media requests related to this project shall be directed to the PCO, and the COR who will forward the required to the NSWCPD Public Release Authority for review.

5.3.4 Any attempt by unauthorized third parties to solicit, obtain, photograph, or record, or; incidents of loss/compromise of government Classified or CI, Business Sensitive, Company Proprietary information related to this or other program must be immediately reported to the contractor's Facility Security Officer and Cognizant Security Office and/or the Naval Criminal Investigative Service, and the NSWC PD Security Division (Code 105).

5.4 RECEIPT, STORAGE, AND GENERATION OF CONTROLLED UNCLASSIFIED INFORMATION (CUI) All Controlled Unclassified Information (CUI) associated with this contract must follow the minimum marking requirements of DoDI 5200.48, Section 3, paragraph 3.4.a, and include the acronym "CUI" in the banner and footer of the document. In accordance with DoDI 5200.48, CUI must be safeguarded to prevent Unauthorized Disclosure (UD). CUI export controlled technical information or other scientific, technical, and engineering information must be marked with an export control warning as directed in DoDI 5230.24, DoDD 5230.25, and Part 250 of Title 32, CFR. Nonfederal information systems storing and processing CUI shall be protected per NIST SP-800-171, or subsequent revisions. All transmissions to personal email accounts (AOL, Yahoo, Hotmail, Comcast, etc.) and posting on social media websites (Facebook, Instagram, Twitter, LinkedIn, etc.) are prohibited. Destroy CUI associated with this contract by any of the following approved methods: A cross-cut shredder; a certified commercial destruction vendor; a central destruction facility; incineration; chemical decomposition; pulverizing, disintegration; or methods approved for classified destruction.

5.5 PLANNING, PROGRAMMING, BUDGETING AND EXECUTION (PPBE) DATA.

When contractor employees, in the performance of their duties, are exposed to Planning, Programming, Budgeting and Execution (PPBE) data, a Non-Disclosure Agreement (NDA) with all affected contactor personnel must be executed in coordination with the COR and PCO to ensure safeguarding disclosure of this data.

5.6 U-NNPI SECURITY REQUIREMENTS

Not applicable.

5.7 U-NNPI

Not applicable.

6.0 PLACE OF PERFORMANCE

All of the work performed in this contract will take place at the vendor’s facility or subcontractor facility.

7.0 TRAVEL

Visits to the vendor by US Navy personnel will be coordinated with the vendor based on specific milestones where such a visit is deemed appropriate by the Government. Intent to visit the vendor’s facility shall be communicated at least twenty-one (21) days prior to such a visit taking place unless requested sooner by the contractor.

8.0 GOVERNMENT FURNISHED PROPERTY

GFP is required for completion of tasks under this SOW. All Government Furnished Property is property of the U.S. Government and shall not be transferred to any individual or agency, public or private, without the express written approval of the originating Contracting Officer except as required for the specific performance of tasks under this task order. Accountability for Government Property under this task order shall be managed in accordance with FAR Part 45 and DFARS Part 245 as well as the Government Property clauses in the Task Order whether acquired by the prime or subcontractors (Contractor Acquired Property), provided by the Government, or received directly from another commercial source as a deliverable from a Government issued contract.

All US Navy property shall be stored indoors, and in compliance with applicable clauses for storing GFP. The contractor shall be responsible for maintaining the condition of, and controlling access to any U.S. Navy assets while the assets are at the contractor’s facility until the time that the assets are delivered back to the U.S. Navy.

Only the Government Furnished Property form (provided as part of this contract package) will be used to identify GFP. These parts will be provided as Government Furnished Property (GFP) at no expense to the contractor.

GFP to be furnished for the repair upon execution of contract after the contract is awarded can be found in Table 1. GFP furnished by the government may not include all part numbers listed per description on Table 1. GE Part numbers provided per stage will be provided at the discretion of the government, but quantities of airfoils per stage will remain the same.

Additional Government Property accountability requirements are outlined in the following Directives and Instructions and shall be adhered to as applicable:

· DODI 4161.02, Accountability &…