Draft SOW_LM2500 HPT Material Repairs.doc

DRAFT Statement of Work (SOW)

2SCOG LM2500 HPT Material Repairs

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 providing gas turbine engine life cycle and engineering support.

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:

(i) Confirm the conduct is in violation and when necessary direct the mode of further performance,

(ii) Countermand any communication regarded as a violation,

(iii) Deny that the conduct constitutes a violation and when necessary direct the mode of further performance, or

(iv) In the event the notice is inadequate to make a decision, advise the Contractor what additional information is required, and establish the date by which it should be furnished by the Contractor.

1.1 BACKGROUND

The marine gas turbine engineering branch (Code 424) of the Naval Surface Warfare Center, Philadelphia Division (NSWCPD) provides engineering and life cycle management support for all propulsion and power generation engines on US Navy surface combatants. Division 42’s major responsibilities include on-site and remote technical support, management of full engine and component level repairs, technical documentation improvements, and hardware/software upgrades.

1.2 SCOPE OF WORK

This specification identifies the general requirements for the refurbishment of LM2500 high pressure turbine blades and nozzles. The government furnished property (GFP) provided under this contract are used LM2500 gas turbine engine hot section parts. They may or may not be repairable for future use in Navy gas turbine engines. It is understood that some components will be deemed unrepairable and will not be returned to the Navy in “A” condition or ready for installation in an engine. Since there are subtle industry variations and approaches to repairing LM2500 components, this statement of work will not dictate all processes and procedures to be used in the refurbishment of these parts. Specific parts requiring repair under this contract are:

2.0 APPLICABLE DOCUMENTS

US Navy LM2500 Technical Manuals:

Depot Level Maintenance: S9234-AB-MMD-020/LM2500 (Dated 3/15//2012); Chapter 8-389; shall be provided with the contract solicitation.

Additional US Navy LM2500 technical manuals will only be provided after contract award to the successful offeror. Due to export control restrictions, they cannot be disseminated widely without justification through the Navy Intellectual Property Office (NIPO). The contractor must request permission from Naval Surface Warfare Center Philadelphia Division (NSWCPD) Code 424 to reproduce Navy manuals. Any US Navy manuals issued, and all copies made, and all printouts generated will remain the property of the US Navy.

3.0 REQUIREMENTS

3.1 GENERAL

The contractor shall furnish services in accordance with the below:

3.2 RECEIPT OF GOVERNMENT FURNISHED PROPERTY

The contractor shall perform an incoming inventory check of US Navy LM2500 GFP within 15 days of receipt at their facility. The receipt inspection is meant to validate the quantity of parts shipped to the contractor. A one-page report documenting the total quantity of parts received and individual quantities of High Pressure Turbine (HPT) blades and nozzles included in the shipment is required (CDRL A001). Photo documentation of the shipment is NOT required. The contractor shall submit an email with the receipt report attached to the technical POC at NSWCPD.

Parts which are deemed candidates for repair shall proceed to the subsequent repair stage. It is understood that some parts may later be deemed not repairable based upon further evaluation during the cleaning process.

3.3 CLEANING AND STRIPPING OF AIRFOIL COATING

The contractor shall clean and strip coating from the Government furnished property (GFP). The stripping practice shall remove airfoil coatings while preserving the parent metal of the component part. Navy GFP parts are coated with either BC 22 (overlay) or Platinum Aluminide (Diffusion) coatings. Individual shipments of parts could contain GFP with both types of coating. Parts coated with Platinum Aluminide will be visually identifiable due to marking on the shank of the part. Those markings will be conveyed 30 days after contract award.

Navy provided blades and nozzles may have an overlay coating (BC 22) or a diffusion coating (Pt-Al) applied to the airfoil. The coatings can be removed via solution bathes or physical processes including grit blast to expose the parent metal of the airfoil. Residual coating shall not be present at the completion of the cleaning and stripping process.

Following the stripping of the coating, the contractor shall inspect the candidate GFP for serviceability. Parts which are deemed candidates for repair shall proceed to the subsequent repair stage. It is possible that parts inspected after the cleaning phase may reveal out of limits conditions which render its reparability impractical.

3.4 SERVICEABILITY INSPECTION

The contractor shall perform an incoming inspection of all Navy provided LM2500 components for serviceability. The offerors shall use industry best practices to assess the parts for reparability. The contractor shall inspect the part number on GFP components to assess its configuration. The service criteria to be utilized to evaluate the parts may be shared with the Navy. The parts can be cleaned or inspected with special equipment as the contractor sees fit to perform this analysis. All Navy parts must be tracked with individual routing documents; the contractor must submit samples of the routing plan for evaluation. Incoming components that display evidence of previous repairs, such as etching, shall be deemed unserviceable/not repairable (second full repair not allowed).

Parts which are deemed candidates for repair shall proceed to the subsequent repair stage, Section 3.5 or Section 3.6. It is understood that some parts may later be deemed as not repairable based upon further evaluation.

Those parts deemed not repairable should be segregated for return to the Navy without further processing. Each part evaluated as not repairable at this phase of incoming inspection should be tagged with a brief explanation of the observations or findings which rendered the parts not 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 not repairable. Non repairable parts shall be slated for bulk shipment back to the Navy.

Industrial standard processes shall be used to evaluate individual parts for repair. This assessment can include air flow and/or water flow testing of the internal cooling passages. The assessment can also include X-ray or sonic evaluations of the component airfoil. The contractor may also use dye penetrant inspection techniques to evaluate the GFP repairability. Any inspections performed on Navy GFM should 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.

Inspection results shall be provided within 90 days of delivery per CDRL A002.

3.5 REFURBISHMENT OF STAGE 1 AND 2 NOZZLES

The contractor shall utilize industry best practices to return the LM2500 hot section component to new part dimensional measurements. Variation of nozzle chordal width greater than 0.010” deviation from nominal production dimensions is not permitted. GFP nozzles will be disassembled to permit the removal of the inserts. Removal of the inserts will require removal of welds/brazes to permit the insert to be extracted.

Cooling holes must be retained open throughout the repair process. At the conclusion of the repair process, all masking agents shall be removed to permit airflow and water flow through the airfoil cooling holes. The contractor shall employ weld and braze buildup processes and repairs as required to restore the original airfoil dimensions to the GFP parts.

Filler material composition shall be provided by the contractor in its summary of the repair package to assess its compatibility with the nozzle parent metal (X40). The contractor shall use filler wire as required to fill cracks on the GFP parts. Following the buildup process, heat tint and treatment may be used as required. Platform and airfoil thickness shall be assessed for serviceability. At the completion of the refurbishment process, belt-sand platform edges for uniform dimensions at the mating edges.

In preparation for coating the nozzles with platinum aluminide following the refurbishment, the contractor must:

· Mask off any trailing edge cooling holes as required.

· Re-install new/replacement nozzle inserts and secure to the platform with braze or weld material.

· Coat the nozzle airfoil and platform surfaces with platinum aluminide coating, normal 0.002-0.003” thickness.

· Check and record Dimension A4 area and assess for service limits.

· Perform a dimensional check of the nozzle at the completion of the refurbishment process.

The GFP components shall be water flow inspected at the completion of the refurbishment cycle as defined in Chapter 8-389 of NSTM S9234-AB-MMD-020/LM2500. This procedure contains specific criteria for nose hole, gill hole and cooling hole flow requirements.

The contractor shall vibropeen a repair part number on the shank of the part to indicate it has been processed through a repair procedure. The contractor shall develop its own part number protocol. The contractor will define its marking protocol to the Navy upon 30 days after contract award.

Throughout the refurbishment process, the nozzles will be individually traceable by use of the contractor’s shop routing documentation. Those documents will be retained and copies provided to the Navy at the completion of the repair process. The document can be as simple as a tag or traveler. The contractor will submit a sample document in its summary submittal to validate the traceability of Navy GFP components (CDRL A003).

3.6 REFURBISHMENT OF STAGE 1 AND 2 BLADES

The contractor shall utilize industry best practices to return the LM2500 hot section component to new part dimensional measurements. Variation in blade length (platform to blade tip) of greater than 0.010” deviation from nominal production dimensions is not permitted. The contractor will employ weld and braze buildup processes and repairs as required to restore the original airfoil dimensions to the GFP parts.

Blades repaired under this contract shall receive Full Repairs Only. Partial repairs which include not stripping the coating from the airfoil are not permitted.

Cooling holes are retained open throughout the repair process. At the conclusion of the repair process, all masking agents shall be removed to permit airflow and water flow through the airfoil cooling holes. The contractor will employ weld and braze buildup processes and repairs as required to restore the original airfoil dimensions to the GFP parts.

Filler material composition will be provided by the contractor in its summary of the repair package to assess its compatibility with the blade parent metal (Rene 80). The contractor shall use filler wire as required to fill cracks and build up the tip region on the GFP parts. Following the buildup process, heat tint and treatment may be used as required. Platform and airfoil thickness shall be assessed for serviceability. At the completion of the refurbishment process, the contractor shall belt-sand platform edges for uniform dimensions at the mating edges.

The Blades will be coated (airfoil and platform surfaces) with platinum aluminide coating, normal 0.002-0.003” thickness. The contractor shall ensure no line of sight application issues will impact blade coating uniformity.

The contractor shall validate in its shop documentation dimensional length of the blade at the completion of the refurbishment process.

The contractor is required to vibropeen a repair part number on the shank of the part to indicate it has been processed through a repair procedure. The contractor shall develop its own part number protocol. The contractor will define its marking protocol to the Navy upon 30 days after contract award.

Throughout the refurbishment process, the blades will be individually traceable by use of the contractor’s shop routing documentation. Those documents will be retained and copies provided to the Navy at the completion of the repair process. The document can be as simple as a tag or traveler. The contractor will submit a sample document in its summary submittal to validate the traceability of Navy GFP components.

3.7 POST REPAIR PACKAGING, INVENTORY, AND SHIPMENT

The contractor shall provide a monthly report of all GFP components at their facility (CDRL A004). The monthly report will categorize individual components as either awaiting repair induction, in repair or refurbished awaiting shipment instructions. The monthly report will be provided on the 1st of each month. The contractor shall submit this monthly report via email to the technical POC at NSWC in Code 424.

If repairs are completed outside the continental United States (CONUS), the contractor 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. Out of CONUS contractors 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 GFP parts back to the Navy.

All repairs shall be completed within 180 days of the award of the associated repair task order.

3.8 TOOLING

The contractor shall possess all supplies and materials necessary to accomplish the refurbishment of LM2500 high pressure turbine nozzles and blades. The contractor owned tooling will include but is not be limited to airflow and water flow benches to permit evaluation of the internal cooling flow passages for these components. The contractor will also own or have under contract the necessary tools and equipment required to apply platinum aluminide coating to the Navy GFP following the refurbishment process.

A list of tooling available and readily accessible by the contractor required for the refurbishment of LM2500 high pressure turbine blades and nozzles shall be included in the contractor proposal for Navy evaluation. The US Navy shall not provide, nor be responsible for, any special support equipment, tooling, or machinery used for the refurbishment of US Navy LM2500 components.

3.9 TECHNICAL APPROVAL

Deviations from the latest revisions of US Navy LM2500 depot level technical manuals, listed in Section 3 of this document, such as waivers, engineering change proposals, material substitutions, engineering directives or alternate repair methods, not specifically stated in the Navy manuals/procedures shall only be permitted after processing deviations and obtaining written approval from the Contracting Officer.

All processes, procedures, inspection criteria, and components used in the overhaul of US Navy LM2500 SST gas generator shall be reviewed by NSWCPD Code 424 and approved by the Contracting Officer for use or implementation in the gas generator overhaul. The US Navy, upon written request, will evaluate supplemental industrial procedures on a case-by-case basis. Commercially equivalent procedures not outlined in the contractor’s summary proposal but developed subsequently will be considered, but are not approved for use without written authorization from the Contracting Officer.

3.10 MANUFACTURING PHASE-OUT OR DISCONTINUATION OF PRODUCTION, DIMINISHING SOURCES, AND OBSOLETE MATERIALS OR COMPONENTS

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

4.1 CDRL A001, RECEIPT AND INVENTORY REPORT

4.1.1 Within 15 days of receipt of material at the vendor facility, the contractor shall contact the U.S. Navy Code 424 TPOC to provide a report which documents the quantities and part types (with name and part number) of all components delivered.

4.2 CDRL A002, REPAIR/SERVICABILITY REPORT

4.2.1 Within 90 days of receipt of material at the vendor facility, the contractor shall contact the U.S Navy Code 424 TPOC to provide a report which documents the quantity of repairable parts broken out by part name and part number.

4.3 CDRL A003, FINAL OVERHAUL REPORT AND TRAVELERS

4.3.1 Within 30 days of completing repairs, the contractor shall contact the U.S. Navy Code 424 TPOC to provide the final overhaul quantities broken out by part name and part type. Travelers, or part tags, shall be sent back with each component to verify condition and work performed.

4.4 CDRL A004, MONTHLY GFP AND STATUS REPORT

4.4.1 On the first day of each month, the contractor shall contact the U.S. Navy Code 424 TPOC to provide a status regarding all the GFP provided for servicing. This report shall document the current condition of components (not repairable, in repair processing, repaired, shipped back to NSWCPD).

5.0 SECURITY REQUIREMENTS

5.1 OPERATIONS SECURITY (OPSEC)

5.1.1 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).

5.1.2 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.

5.1.3 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.

5.1.4 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 105.1). Questions concerning these requirements shall be directed to the PCO, and the COR who will forward the request to the NSWC PD Security Division (Code 105.1).

5.2 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.

6.0 PLACE OF PERFORMANCE

All of the work performed on this contract shall take place at the vendor’s facility.

7.0 TRAVEL

Visits to the vendor by US Navy personnel will be coordinated with the vendor based on specific production 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.

8.0 GOVERNMENT FURNISHED PROPERTY

All US Navy property shall be stored indoors, and in compliance with applicable clauses for storing GFM. 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 asset(s) is (are) delivered back to the U.S. Navy.

The following items are to be furnished to the repair vendor upon execution of task orders after the contract is awarded:

These parts will be provided as Government Furnished Equipment (GFE) at no expense to the contractor. LM2500 HPT components will be provided within 90 days of contract/task order award.

9.0 GOVERNMENT FURNISHED INFORMATION

The following US Navy LM2500 Technical Manual section shall be provided as part of the contract solicitation.

Depot Level Maintenance: S9234-AB-MMD-020/LM2500 (Dated 3/15//2012); Chapter 8-389

Additional US Navy LM2500 technical manuals will only be provided (via email) after contract award to the successful offeror. Due to export control restrictions, they cannot be disseminated widely without justification through the Navy Intellectual Property Office (NIPO). The contractor must request permission from Naval Surface Warfare Center Philadelphia Division (NSWCPD) Code 424 to reproduce Navy manuals. Any US Navy manuals issued, and all copies made, and all printouts generated will remain the property of the US Navy.

10.0 PURCHASES

Not Applicable.

11.0 Counterfeit Material Prevention

Non-Electronic Materials Department of the Navy contractors (and their subcontractors at all tiers) who obtain critical or high risk materiel shall implement a risk mitigation process as follows:

· If the materiel is currently in production or currently available, materiel shall be obtained only from authorized suppliers

· If the materiel is not in production or currently available from authorized suppliers, materiel shall be obtained from suppliers that meet appropriate counterfeit avoidance criteria

· Contractor shall notify the contracting officer when critical or high risk materiel cannot be obtained from an authorized supplier;

· Contractor shall take mitigating actions to authenticate the materiel if purchased from an unauthorized supplier

· Contractor shall report instances of counterfeit and suspect counterfeit materiel to the contracting officer and the GIDEP as soon as the contractor becomes aware of the issue.

12.0 PERSONNEL

Not Applicable.

13.0 NSWCPD Electronic Cost Reporting and Financial Tracking (eCRAFT) System Not Applicable.

14.0 SPECIAL REQUIREMENTS AND ORDERING STRATEGY

Initial orders shall be placed for incoming inspections only. After NSWCPD receives the repair/serviceability report (CDRL A002), a follow-on order will be placed for material repairs based on the results of the incoming inspections. This ordering strategy will help to minimize the amount of open repair quantities in the event that GFP components delivered cannot be serviced back to “A” condition per the refurbishment requirements defined in Section 3.