Spec_Sheet.pdf

STATEMENT OF WORK

FOR

ALLIS CHALMERS VA-1409 AXIAL COMPRESSOR STATOR BLADES

ARNOLD ENGINEERING DEVELOPMENT COMPLEX

ARNOLD AIR FORCE BASE, TN 37389

TABLE OF CONTENTS

1. SCOPE

1.1 Scope

1.2 Item Definition

2 Applicable Documents

2.1 Government Documents

2.2 Non-Government Documents

2.3 Order of Precedence

3 Requirements

3.1 Work Definition

3.2 Materials

3.3 Performance Characteristics

3.4 Physical Characteristics

3.5 Testing

3.6 Workmanship

3.7 Certification

4 Quality Assurance Provisions

4.1 Quality Conformance Inspection Requirements

4.2 Material Qualifications

4.3 Transportation

4.4 Liability

4.5 Final Acceptance Inspections

4.6 Submittal Summary Table

5 Appendix A

5.1 Description of Requirements

5.2 Submittal Procedure

5.3 Specific Submittal Descriptions and Requirements

1. SCOPE

1.1. Scope: This specification establishes the performance and acceptance requirements for replacement stator blades for an axial flow compressor in the Propulsion Wind Tunnel (PWT) facility at Arnold Engineering Development Complex (AEDC).

1.2. Item Definition: Stator blades are an integral component of an Allis Chalmers VA-1409 axial flow compressor. A complete set of stator blades consist of one row of moveable Inlet Guide Vanes (IGV), nine rows of fixed stator blades, one row of straightening vanes (SV), blade nuts and washers. The stator blades are stainless steel forgings, heat treated and precision machined to the dimensions and tolerances specified on the drawings listed in Section 2.

1.2.1. Inlet Guide Vanes: One row of compressor inlet end moveable blades, linked to a sliding ring positioned on the periphery of the stator basket, for setting blade angle positions of -15 to +15 degrees.

1.2.2. Stator Blades: Nine rows of stator blades positioned in the stator basket between the IGV’s and the SV’s and fixed at defined angular positions with high strength nuts and washers.

1.2.3. Straightening Vanes: One row of straightening blades positioned in a stator basket at the compressor discharge end of stator basket and fixed at a defined angular position with high strength nuts and washers.

1.2.4. Nuts and washers: One nut and four washers for each fixed position blade.

2. APPLICABLE DOCUMENTS

2.1. Government Documents: The following drawings, of the exact revision listed below, form a part of this specification to the extent specified herein.

2.1.1. AEDC Drawings:

(1) PUT04365.01 Rev D – VA1409 Inlet Guide Vane Blade Details

(2) PUT04365.02 Rev D- VA1409 Stator Blade Details (S1, S2, S3, S4)

(3) PUT04365.03 Rev B – VA1409 Stator Blade Details (S5, S6, S7, S8, S9)

(4) PUT04365.04 Rev D – VA1409 Straightening Vane Blade Details

(5) PUT04365.08 Rev B – VA1409 Nuts for Compressor Blades

2.2. Non-Government Documents: The following documents of the exact revision listed below form a part of this specification to the extent specified herein.

2.2.1. American Society for Testing and Materials (ASTM)

(1) A370 --- (Latest Revision) Standard Test Methods and Definitions for Mechanical Testing of Steel Products.

(2) A275 --- (Latest Revision) Standard Test Method for Magnetic Particle Examination of Steel Forgings.

(3) E45 --- (Latest Revision) Standard Test Methods for Determining the Inclusion Content of Steel.

2.2.2. International Organization for Standardization

(1) ISO 9001-08 --- Quality Management Systems- Requirements-Fourth Edition

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

3. REQUIREMENTS

3.1. Work Definition:

3.1.1. The Contractor shall supply all equipment, labor, materials, and transportation necessary to fabricate, machine, clean, inspect, and deliver to AEDC up to two (2) complete sets of stator blades (1,398), nuts (1,398), and washers (5,592) in accordance with the drawings listed in paragraph 2.1.1, this specification, and the purchase order. Final acceptance testing of the blades will be by the Government at AEDC.

3.1.2. All work shall be accomplished at a facility with current ISO 9001 certification and at least ten years of experience in the fabrication, machine, clean, and inspect of turbo-machinery axial compressor steel blades. Submit documentation to the Government.

3.1.3. All non-destructive testing (NDT) shall be accomplished by a certified Level II NDT Inspector, with certification in magnetic particle (MT) and ultrasonic (UT) testing. Submit documentation to the Government.

3.2. Materials:

3.2.1. The blades shall be manufactured using consumable electrode vacuum re-melted Type 403 martensitic stainless steel.

3.2.2. The blade material shall meet a cleanliness requirement of 2-12-A when measured in accordance with method B of ASTM E-45.

3.2.3. The nuts shall be manufactured of carbon or low alloy steel and shall exhibit a hardness of 27 - 38 HRC.

3.2.4. The washers shall be manufactured of carbon or low alloy steel and shall exhibit a hardness of 40 - 45 HRC.

3.2.5. The blades shall be inspected after final machining using the wet fluorescent magnetic particle method in accordance with ASTM A275. No relevant indications are acceptable. Submit documentation to the Government.

3.3. Performance Characteristics:

3.3.1. The Contractor shall provide blades which meet the following performance requirements as established for existing compressors with the following name plate data:

VA-1409 Axial Flow Turbo Compressor (Design Parameters)

Manufacturer Allis-Chalmers Manufacturing Company

Inlet Volume 280,000 cfm

Pressure Ratio 3.5 psi (Max)

Inlet Pressure 13.3 psia (Max)

Inlet Temperature 165 deg. F (Max)

Discharge Pressure 27.2 psia (Max)

Discharge Temperature 500 deg. F (Max)

Speed of Compressor 3,600 rpm

3.4. Physical Characteristics:

3.4.1. The blades, nuts, and washers shall be fabricated in accordance with respective drawings as listed in paragraph 2.1.1 of this specification. Perform and record “as-built” dimensions of each blade, nut, and washer after final machining. Submit results to the Government. Microsoft Excel spreadsheet format is acceptable.

3.4.2. Each blade requested by purchase order shall be furnished with one (1) special nut and four (4) spring washers.

3.4.3. The blade materials shall at a minimum exhibit the following physical characteristics:

Ultimate tensile strength 105,000 psi

Yield strength (0.2% offset) 85,000 psi

Elongation in 2 inches 20%

Reduction in area 60%

Impact values (Charpy “V” Notch) 70 deg. F 50 ft-lbs

Impact values (Charpy “V” Notch) -20 deg. F 20 ft-lbs

3.4.4. The nut materials shall at a minimum exhibit the following physical characteristics:

Ultimate tensile strength 127,000 psi

Yield strength at 0.2% offset 103,000 psi

HRC 27 - 38

3.4.5. The spring washer materials shall at a minimum exhibit the following physical characteristic:

Ultimate tensile strength 100,000 psi

Yield strength at 0.2% offset 53,000 psi

HRC 40 - 45

3.4.6. Type: VA 1409 Axial flow Turbo compressor stator blades

Number of Inlet Guide Vanes One hundred and fourteen (114)

Number of Row 1 Stator Blades One hundred and fourteen (114)

Number of Row 2 Stator Blades One hundred and fourteen (114)

Number of Row 3 Stator Blades One hundred and fourteen (114)

Number of Row 4 Stator Blades One hundred and fourteen (114)

Number of Row 5 Stator Blades One hundred and thirty-eight (138)

Number of Row 6 Stator Blades One hundred and thirty-eight (138)

Number of Row 7 Stator Blades One hundred and thirty-eight (138)

Number of Row 8 Stator Blades One hundred and thirty-eight (138)

Number of Row 9 Stator Blades One hundred and thirty-eight (138)

Number of Straightening Vanes One hundred and thirty-eight (138)

3.5. Testing:

3.5.1. The Government reserves the right to witness all testing. The Contractor shall notify the Government two weeks prior to performing machining, tests, and inspections. The Government reserves the right to observe the following operations, as a minimum, at the Contractor’s facility:

(1) Machining process for stator blades

(2) Magnetic particle inspection by the wet fluorescent method

(3) Dimensional inspection of blades

3.6. Workmanship:

3.6.1. All materials to be incorporated into the work shall be of recent manufacture, unused, and in accordance with the requirements of this specification and the applicable material standards.

3.6.2. Thoroughly clean each blade stub shaft threads of all metal shavings and debris to prevent potential for galling with nut at assembly.

3.6.3. Thoroughly clean each nut threads of all metal shavings and debris to prevent potential for galling with blade stub shaft threads at assembly.

3.6.4. Lubricate threads of each nut and threads of each blade stub shaft.

Assemble each nut over the full threaded length of each blade stub shaft to check for galling.

3.7. Certification:

3.7.1. The Contractor shall provide Certified Material Test Reports for the raw material from the producing mill to the Government for approval prior to forming.

3.7.2. A certified report of all test and examination results shall be furnished at the time of shipment of each box of blades. The reports shall be traceable to the individual blades represented. The report shall include the ASTM designation, year date and revision letter, if any.

4. QUALITY ASSURANCE PROVISIONS

4.1. Quality Conformance Inspection Requirements: Quality conformance inspections for the stator blades, nuts, and washers shall consist of the following:

4.1.1. Responsibility for inspection: Unless otherwise specified in the contract, the Contractor is responsible for the performance of all inspection requirements (examinations and tests) as specified by the applicable ASTM standards. Inspections shall be performed on items that are representative of those to be delivered under the contract. The Government reserves the right to perform any of the inspections set forth in this specification where such inspections are deemed necessary to assure supplies and services conform to prescribed requirements. The Contractor shall afford the Government’s inspector all reasonable facilities necessary to satisfy him that the material is being furnished in accordance with the specification. Inspection by the Government will not interfere unnecessarily with the Contractor.

4.1.2. Responsibility for compliance: All items shall meet all requirements of section 3. The absence of any inspection requirements in the specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the Government for acceptance comply with all requirements of the contract.

Sampling inspection, as part of manufacturing operations, is an acceptable practice to ascertain conformance to requirements, however, this does not authorize submission of know defective material, either indicated or actual, nor does it commit the Government to accept defective material.

4.1.3. Non-conformance: Notify the Government immediately if a non-conformance to the stated requirements arises and the contract items cannot be reworked back to the requirements.

4.2. Material Qualifications: The Contractor shall provide forging material samples from each heat in each heat-treat batch after heat treatment to the Government for approval prior to machining. Each material sample shall be sufficient (2 inch round bar x 12 inches long minimum) to provide two full-size round tensile specimens (A370, figure 4) and six full-size Charpy V-notch impact specimens (A370, figure11). If the formed blade blanks are not of sufficient size to provide the samples, a separate piece of the raw material may be heat-treated with the blades for testing.

Samples shall be identified with the mill heat number and the heat treat batch code. Submit material samples of each heat treat to the Government.

4.3. Transportation: The Contractor shall provide all preservation, packing, and packaging to ensure safe delivery of the items to AEDC. The blades shall be shipped to AEDC in plywood boxes. Each row of blades shall have individual boxes. The exterior of the box shall be made of ¾” thick plywood. The interior individual wooden compartments shall be made of ½” thick plywood. The exterior shall have (2) wooden 4” x 4” mounted to the bottom of the box to permit ease of movement using a forklift. Each blade shall be packaged separately in bubble wrap in the compartments within the boxes. One nut and four washers shall be installed on each blade. The Contractor shall provide transportation of all required items to AEDC. Finished surfaces shall be adequately protected to prevent marring, scratching, rust, and contamination. The Contractor shall not use Cosmoline as a surface protectant.

4.4. Liability: The Contractor shall assume liability for the blades from the time the blades are initially loaded onto the Contractor’s transportation vehicle until the time that the blades are received at AEDC. The Government will unload the blades from the Contractor’s vehicle at AEDC.

4.5. Final Acceptance Inspections: The Government will perform the following inspections at AEDC prior to final acceptance:

4.5.1. Dimensional Inspection of eight or more blades arbitrarily selected from each row to verify conformance with drawing details.

4.5.2. Magnetic Particle Inspection of all blades in accordance with ASTM A275, wet florescent method.

4.5.3. A representative sample of the nuts and washers shall be hardness tested in accordance with ASTM A370.

4.6. Submittal Summary Table: Submit the following documentation in accordance with Appendix A – Submittal Procedure.

Table 1 Required Submittal List

No. Section Reference

Submittal Description Due

1 3.1.2 Proof of ISO 9001 certification and proof of at least 10 years of experience in fabrication of axial compressor blades

Prior to contract award

2 3.1.3 Proof of Level II Inspector certification Prior to contract award

3 3.7.1 Material Certification Reports Prior to forming

4 4.2 Material Samples 2 weeks after receiving heat treat

5 3.5.1 Machining, test, and inspection dates 2 weeks prior to machining, testing, and inspection

6 3.1.3 Level II NDT certification 2 weeks after inspection is complete

7 3.2.5 NDE/Magnetic Particle Inspection 2 weeks after inspection is complete

8 3.4.1 As-built dimensions (blades) Within 7 days of shipment

9 3.7.2 Certified tests and examination report Time of shipment

10 4.1.3 Non-conformance At time of findings

5. Appendix A

5.1. Description of Requirements: This section specifies procedural requirements for non-administrative submittals. These submittals are required to amplify, expand, and coordinate other information contained in the contract.

Non-work-related submittals are addressed elsewhere in the contract rather than in the specification and may include items such as: contract progress schedule, permits, payment applications, performance and payment bonds, insurance certificates, and progress reports.

The Contracting Officer may request submittals in addition to those specified when deemed necessary to adequately describe the work covered in the respective sections of the specification or statement of work.

5.2. Submittal Procedure:

5.2.1. Definition: For the purposes of this section, the term “Contractor” denotes the prime Contractor.

5.2.2. Listing: Section 3 and 4 of the specification includes a summarized listing of item submittals requiring approval for the work. The listing is included for the convenience of users of the contract documents.

5.2.3. Risk: Do not proceed with the part of the work covered by an item submittal including purchasing, fabricating, and delivering until approval is received. Machinery, equipment, material, and articles that do not have the required approval shall be installed or used at the risk of subsequent rejection. Any fabrication or other work performed in advance of the receipt of accepted item submittals and approvals shall be entirely at the Contractor’s risk and expense.

5.2.4. Transmittal Timing: Coordinate the preparation and processing of item submittals with the performance of the work. Prepare and transmit each item submittal to the Contracting Officer sufficiently in advance of the performance of related work and other applicable activities. Transmit related item submittals for the same unit of work so that processing will not be delayed by the Government's need to review submittals concurrently for coordination. No delay damages or time extensions will be allowed for time lost in late submittals.

5.2.5. Content: Each submittal shall be complete and in sufficient detail to allow ready determination of compliance with contract requirements. All submittals which are generic and list more information than is specifically required shall be marked to identify required information. Complete AF Form 3000 and attach as cover sheet for each submittal. Contractor may include multiple item numbers on an AF Form 3000.

5.2.6. Language: All item submittals shall be written in English, including documents, notes on drawings, sketches, and/or samples, calculations, manuals, and all other instances of written text and communication.

5.2.7. Units: All item submittals shall be marked or show dimensions and values in the same units as specified in the contract documents.

5.2.8. Review Time: Allow sufficient time so that contract performance will not be delayed as a result of the time required to properly process submittals, including time for re-submittals, if necessary. Allow 14 calendar days for initial Government processing of each submittal.

No extension of time will be authorized because of the Contractor's failure to transmit submittals to the Government sufficiently in advance of the work.

5.2.9. Contractor Certification: All submittals shall be carefully reviewed by an authorized representative of the Contractor prior to submission to the Government. Each submittal shall be dated, signed, and certified by the Contractor as being correct and in strict conformance with the contract documents. No consideration for review by the Government of any Contractor’s submittal will be made for any items which have not been so certified by the Contractor. All noncertified submittals will be returned to the Contractor without action taken by the Government, and any delays caused thereby shall be the total responsibility of the Contractor.

5.2.10.Deviations: Should any item submittals required by the contract documents show deviations from the contract requirement, the Contractor shall make specific mention of such deviations in the letter of transmittal, including stating cost effects, and product and system limitations which may adversely affect the work, in order that if acceptable, suitable action may be taken for proper adjustment of the contract; otherwise the Contractor will not be relieved of the responsibility for executing the work in accordance with the contract documents and the approved submittals.

Contractor shall clearly mark the proposed variation in all documentation and specifically point out deviations from contract requirements in transmittal letters. Failure to point out deviations may result in the Government requiring rejection and removal of such work at no additional cost to the Government. Deviations from contract requirements require Government approval and will only be considered when advantageous to the Government. When proposing deviations, deliver written request to the Contracting Officer, with documentation of the nature and features of the deviation and why the deviation is desirable and beneficial to the Government. If lower cost is a benefit, include an estimate of the cost savings. In addition to documentation required for deviation, include the submittal information required for the item. Allow an additional 14 calendar days beyond normal submittal review period for consideration by the Government of submittals with deviations.

5.2.11.Approved Submittals: The part of the work covered by the approved item submittal may proceed provided it complies with the requirements of the contract documents. Final acceptance will depend upon that compliance. The term “Approved” shall only indicate that there is no exception taken to the submittal. Approval of the item submittal shall not be construed as a complete check, and indicates only that the general method or other information appears to meet the contract requirements. Approval does not relieve the Contractor of the responsibility for any error which may exist. After item submittals have been approved by the Contracting Officer, no re-submittal for the purpose of substituting materials or equipment, or changes to any other information will be considered unless accompanied by an explanation of why a substitution or change is necessary.

5.2.12.Disapproved Submittals: Contractor shall correct disapproved item submittals and resubmit for approval within timeframe noted. If no date is given, Contractor shall submit corrected submittal within 14 calendar days. If the Contractor considers any correction or notation on the returned submittal to constitute a change to the contract drawings, specification, or statement of work the Contractor shall notify the Contracting Officer.

5.2.13.Responsibility: The Government’s review of Contractor submittals shall not relieve the Contractor of the entire responsibility for the correctness of details and dimensions and conformance to the specifications. The Contractor shall assume all responsibility and risk for any mistakes and/or costs due to any errors in submittals.

5.2.14.Inconsistencies: If a conflict or inconsistency arises between an approved item submittal and the contract documents, the contract documents shall govern.

5.3. Specific Submittal Descriptions and Requirements: Submittal requirements for individual units of work are specified in the applicable specification section. Except as otherwise indicated in the individual specification sections or SOW, comply with the following requirements for each type of submittal.

5.3.1. Shop Drawings: These are technical drawings and data specially prepared for this contract including fabrication and installation drawings, setting and seaming diagrams, and coordination drawings (for use on-site). Shop drawings include drawings, diagrams and schedules specifically prepared to illustrate some portion of the work, diagrams and instructions from a manufacturer or fabricator for use in producing the product and as aids to the Contractor for integrating the product or system into the project, or drawings prepared by or for the Contractor to show how multiple systems and interdisciplinary work will be coordinated. Information required on shop drawings includes dimensions, identification of specific products and materials which are included in the work, compliance with specified standards, and notations of coordination requirements with other work. Provide special notations of dimensions that have been established by field measurements.

Highlight, encircle, or otherwise indicate deviations from the contract documents on the shop drawings. Furnish one hard copy and one electronic copy.

5.3.2. Test Plans and Reports: Test plans shall include planned testing, including a description of the test, equipment and supplies needed and step-by-step notation of test activities and tasks. Test reports include reports signed by an authorized official of a testing laboratory that a material, product or system identical to the material, product or system to be provided has been tested in accordance with the specified requirements. Testing shall have been within three years of date of contract award for the project.

Reports also include findings of tests required to be performed by the Contractor on an actual portion of the work or prototype prepared for the project before shipment to the job site, findings of tests made at the job site or on a sample taken from the job site, investigation reports, daily logs and checklists, and final acceptance test and operational test procedures. Furnish three hard copies and one electronic copy of each such report required.

5.3.3. Certificates: These include statements printed on the

manufacturer’s letterhead and signed by the responsible officials of the manufacturer of a product, system or material attesting that the product, system or material meets specification requirements.

Certificates include documentation required of the Contractor, or of a manufacturer, supplier, installer or subcontractor through the Contractor, to further demonstrate the quality of orderly progressions of a portion of the work by documenting procedures, acceptability of methods or personnel qualifications. Examples include confined space entry permits, and text of posted operating instructions. Certificates shall be dated after award of the project contract and clearly name the project. Furnish three hard copies and one electronic copy of each certificate required.

5.3.4. Record (As-Built) Drawings: Record drawings showing final configuration of work accomplished. Show all changes, additions, and deviations from the original contract drawings and documentation. If no changes occur, furnish certification to that effect. Drawings may be redlined hardcopies or electronic drawings, and shall accurately show as-built conditions during the progress of the job. If electronic, furnish drawings on a CD-ROM, in AutoCAD 2005 format or later, including every associated component file of the drawings, including raster images, jpeg, tiff, Excel, and any related items required to view, modify, or manipulate the electronic files.

5.3.5. Miscellaneous Submittals: These are work-related, non-administrative submittals that do not fit in the previous categories, including the following:

(1) Project photographs. Furnish both hard copies and digital files.

(2) Qualification certificates. Furnish one hard copy and one electronic copy.

(3) Warranties.

(4) Test and inspection data and documentation.