LM2500 SOW.docx

Performance Work Statement (PWS) for Commercial Depot Level Overhaul of LM2500 Power Turbine Assemblies, LM2500 Single Shank Turbine Gas Generators, LM2500 Paired Blade Turbine Gas Generators, LM2500+ Gas Generators and LM2500+ Power Turbine Assemblies

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 423, which is responsible for propulsion systems installed on surface combatant ships and amphibious assault crafts.

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 2SCOG/Gas Turbines Life Cycle Support Branch (Code 423) and the Propulsion Systems Division (Code 42) of the Naval Surface Warfare Center, Philadelphia Division (NSWCPD) is responsible for research, development, test and evaluation, engineering, and fleet support for US Navy ships, submarines, military watercraft and unmanned vehicles. NSWCPD Code 42 is the In-Service Engineering Agent (ISEA) for Marine Gas Turbine (MGT) main propulsion systems installed on surface combatant ships and amphibious assault ships. There are over 1,200 gas turbine engines installed aboard naval vessels.

NSWCPD Code 423 manages the 2SCOG Program for the US Navy. The 2SCOG program manages the rotatable pool and repair pipeline for US Navy non-nuclear propulsion assets, which includes MGTs used for propulsion, power generation, and auxiliary power on various US Navy surface and amphibious platforms. MGTs are maintained on a condition basis such that an engine is only removed from service after it has failed. The 2SCOG Program provides funds to overhaul gas turbine engines after they are removed from service.

1.2 LM2500 SCOPE OF WORK (CLIN 0001)

NSWCPD Code 423 has the requirement for commercial depot level overhaul of US Navy, US Coast Guard, Military Sealift Command and Foreign Military Navy LM2500 Power Turbine Assemblies (PTAs), National Stock Number (NSN) 2S 2835-01-032-9124, Single Shank Turbine (SST) Gas Generators, NSN 2S 2835-01-237-1153, and LM2500 Paired Blade Turbine (PBT) Gas Generators, NSN 2S 2835-01-032-9125. The LM2500 was designed and manufactured by General Electric (GE) and is utilized by the US Navy as the MGT engine aboard over 300 surface combatants including CG-47, DDG-51 and LCS-2 Class ships.

2.0 APPLICABLE DOCUMENTS

While every effort has been made to ensure the completeness of this list, document users are cautioned that they shall meet all specified requirements cited in Sections 3.0 and 4.0 of this specification, in addition to the specifications listed in the documents listed in Section 2.1.

2.1 GOVERNMENT FURNISHED INFORMATION (GFI)

US Navy LM2500 Organizational Level Technical Manual S9234-AD-MMO-070/LM2500 latest revision

US Navy LM2500 Depot Level Maintenance Technical Manual S9234-AB-MMD-010/LM2500 latest revision

US Navy LM2500 Depot Level Maintenance Technical Manual S9234-AB-MMD-020/LM2500 latest revision

US Navy LM2500 Depot Level Maintenance Technical Manual S9234-AB-MMD-030/LM2500 latest revision

US Navy LM2500 Depot Level Maintenance Technical Manual S9234-AB-MMD-040/LM2500 latest revision

US Navy LM2500 Depot Level Maintenance Technical Manual S9234-AB-MMD-050/LM2500 latest revision

US Navy LM2500 Depot Level Maintenance Technical Manual S9234-AB-MMD-060/LM2500 latest revision

The US Navy LM2500 technical manuals will be provided after contract award to the successful Contractor(s) as Government Furnished Information (GFI). The Contractor must request permission from NSWCPD Code 423 to reproduce the manuals. Any US Navy manuals issued, and all copies made, and all printouts generated will remain the property of the US Navy. Additionally, the US Navy LM2500 technical manuals contain GE proprietary information, which is disclosed in confidence. The GE proprietary information is the property of GE and shall not be used, disclosed to others or reproduced without express written consent from GE. GE proprietary information is not to be used in creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or configuration changes or to obtain Federal Aviation Administration (FAA) or any other Government or regulatory approval to do so.

When available, copies of the Marine Gas Turbine Information System (MGTIS) logbook will be provided at the Task Order level to the Contractor for each US Navy LM2500 undergoing commercial overhaul.

A list of consumable material for each US Navy LM2500 PTA is provided as Attachment 001. A list of consumable material for each US Navy LM2500 SST gas generator is provided as Attachment 002. A list of consumable material for each US Navy LM2500 PBT gas generator is provided as Attachment 003. This consumable material will not be considered as over and above items.

In the event of a conflict between the text of this document and the references cited herein, the US Navy LM2500 technical manuals listed in Section 2.1 of this document take precedence. These manuals are as follows: Organizational Level Maintenance S9234-AD-MMO-070/LM2500 latest revision and Depot Level Maintenance S9234-AB-MMD-010/LM2500 through S9234-AB-MMD-060/LM2500 latest revision.

3.0. REQUIREMENTS (LM2500 PTA, CLIN 0001)

3.1 GENERAL

The Contractor shall overhaul, modify, incorporate mandatory updates, maintain standard configuration integrity, assemble, test, preserve, package, document, mark and prepare for shipment the US Navy LM2500 PTA in accordance with (IAW) this specification.

All overhaul work performed under this specification shall be IAW the current US Navy LM2500 depot level technical manuals, S9234-AB-MMD-010 through S9234-AB-MMD-060 latest revision, as applicable for the articles under overhaul. Any and all deviations from these technical manuals must be approved, in writing prior to incorporating, by the cognizant technical representative at NSWCPD prior to implementation IAW Contract Data Requirement List (CDRL) A004 – Request for Waiver or Deviation.

All overhaul work performed under this specification shall be for articles to be modified to standard configuration, overhauled and delivered Ready For Issue (RFI) to the fleet. All parts not being replaced with new shall be cleaned IAW procedures outlined in US Navy LM2500 depot level technical manual S9234-AB-MMD-010/LM2500 Chapter 3 or US Navy approved equivalent standard commercial procedures. The overhauled LM2500 PTA shall be free of all corrosion when delivered to the US Navy.

If, after contract award, the Contractor proposes to use repair procedures (which are not specifically allowable under the current PWS) to complete the engine overhaul, the Contractor must request approval from NSWCPD Code 423, the NSWCPD Code 0231 Contracting Officer Representative (COR), and Procuring Contracting Officer (PCO) to use any alternate repair procedures, IAW CDRL A004 – Request for Waiver or Deviation.

In addition to NSN and part number (PN) markings contained herein, overhauled units shall be marked, IAW standard commercial practice and DFARS Clause 252.211-7003 “Item Unique Identification and Valuation,” with the delivery order number and date of overhaul.

3.2 TEST CELL

The Contractor shall, at a minimum, have an operational, calibrated test cell and overhaul facility. The Contractor’s gas turbine test cell facility shall, at a minimum, be in the thirty thousand (30,000) pound thrust class. The Contractor shall test for mechanical checkout, seal break-in and acceptable performance throughout the entire range of operation from start through the full rated power. The Contractor shall use a gas generator driver to perform functional testing as follows: rotation, vibration (limits: steady state = 1.0 mils, transient = 1.5 mils), starting, restarting and overspeed transducer output voltage. Procedure, testing points, instrumentation, and the instrumentation ranges and tolerances required to measure function and performance are specified in the US Navy LM2500 depot level technical manual S9234-AB-MMD-040/LM2500 Chapter 22.

In the event of a failure in the testing or an overspeed, additional tests (penalty tests) shall be performed to ensure that the mechanical deficiency was corrected by the maintenance performed; however, the complete testing of the PTA shall be performed in conjunction to these additional tests.

3.3 GOVERNMENT FURNISHED MATERIAL (GFM), GAS TURBINE CHANGE (GTC) UPGRADE KITS (CDRL A009)

The Contractor shall supply and only use US Navy approved parts in the overhaul of US Navy LM2500 PTA. All approved parts for use in US Navy LM2500 PTA are listed in the US Navy LM2500 Illustrated Parts Breakdown S9234-AD-MMO-070/LM2500 latest revision. The use of aftermarket (non Original Equipment Manufacturer (OEM) approved) parts is not permitted.

The US Navy will provide the Contractor with selected US Navy LM2500 Gas Turbine Change (GTC) upgrade kits IAW CDRL A009 – Government Furnished Material (GFM), by National Stock Number. These kits will be provided as GFM at no expense to the Contractor. The GTC upgrade kits listed in Table 1 below are required to be installed, unless found to be previously incorporated, on an as needed basis, as determined per the teardown and inspection of the PTA.

The Contractor shall request the kits needed upon completion of teardown and inspection from NSWCPD Code 423 who will provide them upon request. When the US Navy LM2500 PTA is inducted, NSWCPD Code 423 can provide the Contractor with what GTCs are installed based on MGTIS, but it is required that the Contractor inspect and verify for certainty which GTC upgrade kits need to be requested. If a GTC upgrade kit(s) is already installed on the PTA, the Contractor is required to repair the kit(s), as necessary.

ECPN274GTC875-5

ECPN274GTC875-6

Table 1 – Required Technical Directive Upgrade Kits (provided as GFM, as needed)

All US Navy material 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 US Navy assets while the assets are at the Contractor’s facility until the time that the asset(s) is (are) delivered to a US Navy facility, IAW applicable clauses for material storage and control of GFM.

3.4 LM2500 PTA DISASSEMBLY INSPECTION REPORT (DIR), WORK SCOPE MEETING AND FINAL INVOICE (CDRL A002)

Prior to the work scope meeting, the Contractor shall provide the final Disassembly Inspection Report (DIR) and proposed work scope changes to NSWCDPD Code 423, COR and PCO for review IAW CDRL A002 – DIR. The Final DIR shall include any and all requested Over and Above (O&A) IAW DFARS 252.217-7028. O&A not included on the Final DIR will not be accepted. O&A shall be submitted to the PCO, COR, and Contract Specialist via O&A Submission Template (Attachment 004).NSWCPD Code 42 will perform a visual inspection of all items deemed non-serviceable. Any proposed deviations can be reviewed at this time. Upon NSWCPD review of the proposed DIR and proposed work scope changes, any clarifications requested by NSWCPD based on the DIR recommendations must be adjudicated. Upon review of the DIR and the proposed work scope changes by NSWCPD Code 423, the Contractor shall proceed with arranging the work scope meeting date. During the work scope meeting NSWCPD Code 423 will perform a technical assessment regarding work proposed outside the standard repair to return the asset to RFI status prior to commencing re-build of the engine(s).

After completion of teardown and inspection the Contractor shall provide a DIR detailing all work necessary to return the engine to an RFI condition, including specific details on parts replaced and parts deemed to be serviceable.

The US Navy LM2500 PTA shall have the overhaul work, included but not limited to, identified in Sections 3.4.1 through 3.5 of this specification performed during the overhaul.

3.4.1 Power Turbine Rotor Assembly

Disassemble, inspect, clean, and process as described below and per procedures outlined in the US Navy LM2500 depot level technical manuals.

1. Inspect rotor components per paragraphs 18.37 – 18.39 of US Navy LM2500 depot level technical manual.

1. Install new stage 1 through 6 PTA blades.

1. Install new stage 1 through 6 PTA blade interlocks.

1. Install new interstage seal bolts IAW GTC 64R1.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

3.4.2 Stator Case Assembly

Disassemble, inspect, clean, and process as described below and per procedures outlined in the US Navy LM2500 depot level technical manuals.

1. Inspect stator components per paragraph 18.2 of US Navy LM2500 depot level technical manual.

1. Install new stages 2 and 3 PTA vanes.

1. Incorporate GTC 87 (Cast 6 Segment Vanes Stg. 4 - 6).

1. Install new configuration honeycomb PTA insulation shield/covers.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

3.4.3 Frame, Bearings and Seals

Disassemble, inspect, clean, and process as described below and per procedures outlined in the US Navy LM2500 depot level technical manuals.

1. Replace all main bearing numbers 6, 7R and 7B with new.

1. Pressure test frame per paragraph 18.136 of US Navy LM2500 depot level technical manual.

1. Inspect air and oil seals per paragraph 18.16 – 18.17 of US Navy LM2500 depot level technical manual.

1. Inspect mount uniballs.

1. Inspect D sump forward and aft oil/air seal silver rub strips for corrosion/loss of material.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

3.4.4 Controls and Accessories

Disassemble, inspect, clean, and process as described below and per procedures outlined in the US Navy LM2500 depot level technical manuals.

a. Inspect and test overspeed transducers per paragraph 47.18 of US Navy LM2500 depot level technical manual.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

3.5 LM2500 POWER TURBINE UPGRADE CONFIGURTION AFTER OVERHAUL

All US Navy LM2500 PTAs shall have the mandatory GTC upgrade kits, listed in Table 1 incorporated during the overhaul, if not previously incorporated. NSWCPD Code 423 will provide the GTC upgrade kits as GFM IAW CDRL A009 – Government Furnished Material (GFM), by National Stock Number as listed in Section 3.3 to the Contractor at no cost to the Contractor.

US Navy LM2500 PTA GTC upgrade kits shall only be requested if the kit is required for the overhaul. These kits shall be used for upgrading of the PTA only. If the PTA being overhauled previously had one of the GTC upgrade kits listed in Section 3.3 incorporated, the upgrade kit for that GTC shall not be requested, except when upgrade kit incorporation is necessary to maintain standard configuration. Determination of what GTC upgrade kits are needed is the responsibility of the Contractor. The tables/information that outline which GTC upgrade kits are needed for the corresponding part numbers/serial numbers are found in the GTC along with the detailed installation instructions. Information regarding which GTC upgrade kits are incorporated on the PTA that arrives at the Contractor’s facility will be provided by NSWCPD Code 423 electronically via email. NSWCPD Code 423 will also provide, electronically via email, information regarding PTA miscellaneous maintenance and operational log history.

All material required to complete the overhaul shall be identified in the DIR, prior to the work scope meeting. All material required to complete the overhaul shall be procured by the Contractor. The Contractor shall only use parts identified in the LM2500 Illustrated Parts Breakdown S9234-AD-MMO-070.

4.0 REQUIREMENTS (LM2500 SST, CLIN 0001)

4.1 GENERAL

The Contractor shall overhaul, modify, incorporate mandatory updates, maintain standard configuration integrity, assemble, test, preserve, package, document, mark and prepare for shipment the LM2500 SST gas generator IAW this specification.

All overhaul work performed under this specification shall be IAW the current US Navy LM2500 depot level technical manuals, S9234-AB-MMD-010 through S9234-AB-MMD-060 latest revision, as applicable for the articles under overhaul. Any and all deviations from these technical manuals must be approved, in writing prior to incorporating, by the cognizant technical representative at NSWCPD prior to implementation IAW CDRL A004 – Request for Waiver or Deviation.

All overhaul work performed under this specification shall be for articles to be modified to standard configuration, overhauled and delivered RFI to the fleet. All parts not being replaced with new shall be cleaned IAW procedures outlined in US Navy LM2500 depot level technical manual S9234-AB-MMD-010/LM2500 Chapter 3 or US Navy approved equivalent standard commercial procedures. The overhauled LM2500 SST gas generator shall be free of all corrosion when delivered to the US Navy.

If, after contract award, the Contractor proposes to use repair procedures (which are not specifically allowable under the current PWS) to complete the engine overhaul, the Contractor must request approval from NSWCPD Code 423, the NSWCPD Code 0231 COR, and PCO to use any alternate repair procedures, IAW CDRL A004 – Request for Waiver or Deviation.

In addition to NSN and PN markings contained herein, overhauled units shall be marked, IAW standard commercial practice and DFARS Clause 252.211-7003 “Item Unique Identification and Valuation,” with the delivery order number and date of overhaul.

4.2 TEST CELL

The Contractor shall, at a minimum, have an operational test cell and overhaul facility. The Contractor’s gas turbine test cell facility shall, at a minimum, be in the thirty thousand (30,000) pound thrust class. The Contractor shall test for both proper function and performance throughout the entire range of operation from start through the full power rating. The Contractor shall be fully capable of performing the following: functional testing of the gas generator including vibration, starting, restarting, and acceleration. Expected performance guidelines are outlined in Section 4.6. Procedures, testing points, instrumentation, and the instrumentation ranges and tolerances required to measure function and performance are specified in the US Navy LM2500 depot level technical manual S9234-AB-MMD-030/LM2500 Chapter 13.

In the event of a failure in the testing, additional tests (penalty tests) shall be performed to ensure that the mechanical deficiency was corrected by the maintenance performed; however, the complete testing of the gas generator shall be performed in conjunction to these additional tests.

All accessories shall be tested individually IAW the testing procedures outlined in the most recent version of the US Navy LM2500 depot level technical manuals. Copies of the accessories test reports shall be provided to NSWCPD Code 423, IAW CDRL A002 – Disassembly and Inspection Report.

The fuel used during testing of the gas generator shall be either JP-5, Jet A1, JP-8, Jet A or marine diesel. Natural gas with a comparable heating value can be used. If using natural gas, the Contractor shall submit a justification for correlation to liquid fuel performance. The gas generator shall be the standard US Navy configuration once the overhaul is completed and the gas generator is shipped back to the US Navy.

The test cell shall, at a minimum, have the instrumentation requirements to meet or exceed the associated ranges and tolerances specified in Table 13-3 of the US Navy depot level technical manual S9234-AB-MMD-030/LM2500 latest revision.

The Contractor shall not use slave component accessories installed on the US Navy LM2500 SST gas generator during post overhaul performance testing. Accessories to be delivered with the overhauled gas generator shall be tested during post overhaul performance test of the gas generator in addition to individual testing noted previously.

4.3 GOVERNMENT FURNISHED MATERIAL (GFM), GAS TURBINE BULLETIN (GTB), GAS TURBINE CHANGE (GTC) UPGRADE KITS

The Contractor shall supply and only use US Navy approved parts in the overhaul of US Navy LM2500 SST gas generator. All approved parts for use in US Navy LM2500 SST gas generator are listed in the US Navy LM2500 Illustrated Parts Breakdown S9234-AD-MMO-070/LM2500 through S9234-AD-MMO-090/LM2500 latest revision. The use of aftermarket (non OEM approved) parts is not permitted.

The US Navy will provide the Contractor with selected US Navy LM2500 GTB and GTC upgrade kits IAW CDRL A009 – GFM, by National Stock Number. These kits will be provided as GFM at no expense to the Contractor. The GTB/GTC upgrade kits listed in Table 2 below, with the exception of GTC 100R4 (optional workscope meeting discussion item), are required to be installed, unless found to be previously incorporated, on an as needed basis, as determined per the teardown and inspection of the engine.

The Contractor shall request the kits needed upon completion of teardown and inspection from NSWCPD Code 423, who will provide them upon request. When the US Navy LM2500 SST gas generator is inducted, NSWCPD Code 423 can provide the Contractor with what GTB and GTC kits are installed based on the engine logbooks, but it is required that that Contractor inspect and verify for certainty which GTB/GTC upgrade kits need to be requested from the US Navy. If a GTB/GTC upgrade kit is already installed on the engine, the Contractor is required to repair the kit(s), as necessary.

12/8/2004 (Latest Revision)

GTC 100R4

(Optional)

Table 2 – Required Technical Directive Upgrade Kits (provided as GFM, as needed)

All US Navy material 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 US Navy assets while the assets are at the Contractor’s facility until the time that the asset(s) is (are) delivered to a US Navy facility, IAW applicable clauses for material storage and control of GFM.

4.4 LM2500 SST GAS GENERATOR DISASSEMBLY INSPECTION REPORT, WORK SCOPE MEETING AND FINAL INVOICE (CDRL A002)

Prior to the work scope meeting the Contractor shall provide the final Disassembly Inspection Report and proposed work scope changes to NSWCDPD Code 423, COR and PCO for review IAW CDRL A002 – DIR. The Final DIR shall include any and all requested Over and Above (O&A) IAW DFARS 252.217-7028. O&A not included on the Final DIR will not be accepted. O&A shall be submitted to the PCO, COR, and Contract Specialist via O&A Submission Template (Attachment 004).NSWCPD Code 42 will perform a visual inspection of all items deemed non-serviceable. Any proposed deviations can be reviewed at this time. Upon NSWCPD review of the proposed DIR and proposed work scope changes, any clarifications requested by NSWCPD based on the DIR recommendations must be adjudicated. Upon review of the DIR and the proposed work scope changes by NSWCPD Code 423, the Contractor shall proceed with arranging the work scope meeting date. During the work scope meeting NSWCPD Code 423 will perform a technical assessment regarding work proposed outside the standard repair to return the asset to RFI status prior to commencing re-build of the engine(s).

The Contractor shall perform a complete teardown and inspection of the US Navy LM2500 SST gas generator, except for parts designated to be replaced with new. The Contractor shall also visually inspect gas generator external components and visible flanges, control and accessories piping, electrical leads, clamps, brackets, nuts, bolts, etc. for damage, wear, deterioration, looseness, proper configuration, etc. All US Navy LM2500 SST gas generator accessories shall be inspected IAW inspection criteria outlined in the US Navy LM2500 depot level technical manuals.

After completion of teardown and inspection the Contractor shall provide a DIR detailing all work necessary to return the engine to an RFI condition, including specific details on parts replaced and parts deemed to be serviceable.

The US Navy LM2500 SST gas generator shall have the overhaul work, included but not limited to, identified in Sections 4.4.1 through 4.6 of this specification performed during the overhaul.

4.4.1 Compressor Front Frame Assembly

Disassemble, inspect, clean, and process as described below and per procedures outlined in the US Navy LM2500 depot level technical manuals.

a. Inspect compressor front frame (CFF) for corrosion and missing paint. Also check mounting bushing and inner bushing for wear.

b. Replace oil supply tube “O” Ring, PN J221P020 per Figure 9-36, Item 3 in S9234-AB-MMD-030/LM2500.

c. Replace oil supply tube “O” Ring, PN J221P011 per Figure 8-58, Item 39 in S9234-AD-MMO-070/LM2500.

d. Replace compressor air seal, per Figure 8-8, item 8 of US Navy LM2500 organizational level technical manual, original Phenalic seals PN 9654M03G03 and 9654M03G06 with Teflon seal PN L44765G01.

e. Replace No. 3 bearing stationary oil seal, per Figure 8-8, item 16 of US Navy LM2500 organizational level technical manual, original Phenalic seals PN 9654M23P03 and 9654M23P04 with METCO 601 seal PN L47033G05.

f. Replace No. 3 main bearing with new bearing per Paragraph 8.42 of US Navy LM2500 depot level technical manual.

g. Pressure test sumps.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.4.2 Compressor Rotor Assembly

Disassemble, inspect, clean, and process as described below and per procedures outlined in the US Navy LM2500 depot level technical manuals.

a. All stage 1 compressor blades shall be replaced with new material 100%. The Contractor shall validate the carboloy pads on the stage 1 blades have full 0.020” thickness pads.

b. Steam clean compressor, disassemble, inspect and process.

c. Map all compressor rotor balance weights IAW depot level technical manual. Per US Navy LM2500 depot level technical manual:

1. 3 - 9 spool not to exceed 10 weights.

2. 10th stage disc not to exceed 3 weights.

3. 11 - 13 spool not to exceed 16 weights.

4. 14 - 16 spool not to exceed 12 weights.

5. Complete compressor rotor shall not exceed 24 total weights.

1. Remove all stage 2 through 16 compressor blades for inspection, processing and recoating of dovetails. Repair/process all stage 2 through 16 compressor blades and tip lengthen to obtain optimum blade tip/compressor case clearance in each stage.

1. Inspect for blade platform end gap clearance. If minimum gap is exceeded, install additional wide platform blades as required to obtain proper end gap clearance.

1. Strip any existing rotor land coating IAW Paragraphs 8.217 and 8.232 of US Navy LM2500 depot level technical manual. Apply new rubcoat to compressor rotor stages 3 through 16.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.4.3 Compressor Front Stator Assembly

Disassemble, inspect, clean, and process as described below and per procedures outlined in the US Navy LM2500 depot level technical manuals.

a. Disassemble, clean and process.

b. Inspect variable stator vane (VSV) shroud per Paragraph 8.184/Table 8-68 of US Navy LM2500 depot level technical manual.

c. Apply new rubcoat to compressor front stator case. Strip old Rub and Bond coating IAW Paragraph 8.150 of US Navy LM2500 depot level technical manual.

d. Remove all inlet guide vanes (IGV) through stage 11 compressor vanes for inspection and processing.

e. Remove borescope plugs, inspect, and apply antiseize.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.4.4 Compressor Rear Stator Assembly

Disassemble, inspect, clean, and process per procedures outlined in the US Navy LM2500 depot level technical manual.

1. Apply new rubcoat to compressor rear stator case. Strip old Rub and Bond coating IAW Paragraph 8.159 of US Navy LM2500 depot level technical manual.

1. Remove all stage 12 through 16 compressor vanes for inspection and processing.

1. Remove borescope plugs, inspect, and apply antiseize.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals. These items should be clearly defined in the final engine overhaul reports as having been repaired to re-establish service criteria.

4.4.5 Compressor Rear Frame Assembly

Disassemble, inspect, clean, and process per procedures outlined in the US Navy LM2500 depot level technical manual.

1. Inspect compressor rear frame (CRF) internal hub and strut fillets for cracks.

1. Inspect and test CRF oil tubes for cracks.

1. Replace “O” rings on oil supply tubes.

1. Replace piston rings on No. 4R seal with PN 9693M18P04 (Kit No. 537L180G01) rings.

1. Replace compressor rear case (CRC) to CRF bolts with PN 9665M50P12.

1. Dimensional inspect No. 4B stationary oil seal 9693M49P06 and re-identify per CID 609543.

1. Replace No. 4R and No. 4B main bearings with new bearings per Paragraph 8.42 of US Navy LM2500 depot level technical manual.

1. Remove borescope plugs, inspect, and apply antiseize.

1. Pressure test sumps.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.4.6 Combustor Assembly

Disassemble, inspect, clean, and process per procedures outlined in the US Navy LM2500 depot level technical manual.

1. Disassemble, inspect, clean, and process.

1. Remove combustor and replace hastelloy dome with HS 188 dome PN 9101M95G24. The Contractor is responsible for providing the replacement HS 188 dome. Inspect per Paragraph 8.305 of US Navy LM2500 depot level technical manual.

NOTE: Incoming gas generator may already have an HS 188 dome installed, replacement is not necessary. Remove existing HS 188 dome, inspect, clean, process and reinstall. The dome assembly should be inspected for serviceability and repairs incorporated as necessary.

1. All serviceable fuel nozzles require complete overhaul IAW US Navy LM2500 depot level technical manual. Flow test only is not acceptable.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.4.7 High Pressure Turbine Stage 1 Nozzle Assembly

Disassemble, inspect and process per Paragraphs 8.385 through 8.390 of US Navy LM2500 depot level technical manual.

1. All HPT nozzles will be provided as GFM. The Contractor will disassemble the existing nozzles and carefully store those components for return to the US Navy. The replacement nozzles will be provided by NSWCPD.

1. Replace all HPT stage 1 shrouds with new material 100%. The new shroud material will be provided by the Contractor. The Contractor will disassemble the existing shrouds and carefully store those components for return to the US Navy.

Note: Any conditions found on remaining, non-replaced assembly component that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.4.8 High Pressure Turbine Stage 2 Nozzle Assembly

Disassemble, inspect and process per paragraphs 8.385 through 8.390 of US Navy LM2500 depot level technical manual.

1. All HPT nozzles will be provided as GFM. The Contractor will disassemble the existing nozzles and carefully store those components for return to the US Navy. The replacement nozzles will be provided by NSWCPD.

1. Replace all HPT stage 2 shrouds with new material 100%. The new shroud material will be provided by the Contractor. The Contractor will disassemble the existing shrouds and carefully store those components for return to the US Navy.

Note: Any conditions found on remaining, non-replaced assembly components that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.4.9 High Pressure Turbine Rotor Assembly

Disassemble, inspect and process per Paragraphs 8.385 through 8.390 of US Navy LM2500 depot level technical manual.

1. All HPT blades will be provided as GFM. The Contractor will disassemble the existing rotor assemblies and remove the Stage 1 and 2 blades and carefully store those components for return to the US Navy. Replacement blades will be provided by NSWCPD.

1. Inspect the following:

1. Forward rotating air seals.

2. Coupling nut, including silver plating.

3. Forward shaft.

4. Stage 1 disk.

5. Stage 1 blade retainer.

6. Thermal shield.

7. Stage 2 disk.

8. Stage 2 blade retainer.

9. Rear shaft.

1. Remove aft shaft, pressure tube and inspect.

1. Remove borescope plugs, inspect IAW US Navy LM2500 depot level technical manual, including silver replating/apply antiseize.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.4.10 Turbine Mid Frame Assembly

Disassemble, inspect, clean, and process per procedures outlined in the US Navy LM2500 depot level technical manual.

1. Inspect turbine mid frame (TMF) liner for cracks and distortion.

1. Replace No. 5 and 6 bearing heat shields.

1. Install PN 9084M64 oil inlet tube on all TMF(s) processed. Remove and replace PN 9677M81 old style tubes.

1. Replace No. 5 main bearing with new bearing per Paragraph 8.42 of US Navy LM2500 depot level technical manual.

1. Replace No. 6 main bearing with new bearing per Paragraph 8.42 of US Navy LM2500 depot level technical manual.

1. Remove borescope plugs, inspect, and apply antiseize.

1. Pressure test sumps.

1. Incorporate GTB 24R1, as applicable.

1. Remove LPT Stage 1 nozzles, clean and inspect. All serviceable nozzles shall be stripped and recoated with Platinum Aluminide (PtAl).

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.4.11 Inlet Gearbox Assembly

Disassemble, inspect, clean, and process per procedures outlined in the US Navy LM2500 depot level technical manual.

1. Disassemble to allow for inlet gearbox (IGB) bearing processing.

1. Install IGB nut, PN L16569P04 per Figure 8-51, item 41 of US Navy LM2500 organizational level technical manual.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.4.12 Transfer/Accessory Gearbox Assembly

Disassemble, inspect, clean, and process per procedures outlined in the US Navy LM2500 depot level technical manual.

1. Disassemble to allow for accessory gearbox (AGB) bearing processing. Replace any AGB bearing which exceeds manual inspection criteria with new bearing.

1. Inspect accessory gearbox mounting link and rod ends for spherical ball bearings wear, fretting, and looseness.

1. Replace air/oil separator, per Figure 8-53, item 2 of US Navy LM2500 organizational level technical manual, original Phenalic seals PN 9634M44P02 and 9634M44P04 with Teflon seals PN 9634M44P06 or 9634M44P07.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.4.13 Accessories

Disassemble, inspect, clean, and process per procedures outlined in the US Navy LM2500 depot level technical manual.

1. Inspect and test speed sensor per Paragraph 47.11 of US Navy LM2500 depot level technical manual.

1. Remove and inspect starter for foreign object damage. Comply with gas turbine changes to meet requirements of Section 4.5.

1. Remove main fuel control and bench test per Paragraph 24.78 of US Navy LM2500 depot level technical manual. Comply with gas turbine changes to meet requirements of Section 4.5.

1. Remove fuel pump, inspect and clean strainer element. Test per Paragraph 26-16 of US Navy LM2500 depot level technical manual. Comply with gas turbine changes to meet requirements of Section 4.5.

1. Inspect, clean, test, or replace main fuel filter element per Chapter 27 of US Navy LM2500 depot level technical manual.

1. Remove and bench test fuel shut-off valves per Paragraph 29.13 of US Navy LM2500 depot level technical manual.

1. Remove and bench test compressor inlet temperature (CIT) sensor per Paragraph 25.13 of US Navy LM2500 depot level technical manual. Comply with gas turbine changes to meet requirements of Section 4.5.

1. Remove, inspect and test all electrical cables for wear of braid and interface connectors for integrity, cleanliness and seals.

1. Inspect and test VSV feedback cable per Paragraph 47.6 of US Navy LM2500 depot level technical manual.

1. Inspect and repair as required and test power level angle (PLA) actuator.

1. If accelerometer is determined not ready for issue, replace with new. The calibration schedule for the installed accelerometer shall extend for at least one year beyond the completion date for the engine it is installed upon.

1. Inspect PT 5.4 probes, pigtails, and manifold per Paragraph 47.7 of US Navy LM2500 depot level technical manual.

1. Inspect fuel manifold for end connector cracks.

1. Inspect and test overspeed transducer leads per Paragraph 47.18 of US Navy LM2500 depot level technical manual.

1. Lube and scavenge pump – perform bench test. Repair/replace if limits are not met per Chapter 33 of US Navy LM2500 depot level technical manual.

1. Pressurizing valve – perform bench test. Repair/replace if limits are not met per Paragraph 28.13 of US Navy LM2500 depot level technical manual.

1. Fuel filter assembly – perform bench test. Repair/replace if limits are not met per Paragraph 27.12 of US Navy LM2500 depot level technical manual.

1. VSV actuator – perform bench test. Repair/replace if limits are not met per Paragraph 32.13 of US Navy LM2500 depot level technical manual.

1. Inspect and test resistance temperature detectors (RTD) per Paragraph 47.10 of US Navy LM2500 depot level technical manual.

1. Inspect and test spark igniter per Paragraph 47-16 of US Navy LM2500 depot level technical manual and per General Electric Service Letter No. 2500-04-01, dated 29 September 2004.

1. Inspect and test ignition exciter per Chapter 39 of US Navy LM2500 depot level technical manual. If inducted US Navy LM2500 SST gas generator is configured with Digital Fuel Control (DFC), inspect, clean and bench test CIT/compressor inlet pressure (CIP) sensor per Paragraph 47.22 of US Navy LM2500 depot level technical manual.

1. If inducted US Navy LM2500 SST gas generator is configured with DFC, inspect, clean, repair and test hydraulic lube oil filter per Chapter 48 of US Navy LM2500 depot level technical manual.

1. If inducted US Navy LM2500 SST gas generator is configured with DFC, remove VSV actuator (PN L34358Pxx) and turn into Original Equipment Manufacturer (OEM), Woodward, for clean, inspection, returned to as new condition and final test per OEM standards and procedures.

1. If inducted US Navy LM2500 SST gas generator is configured with DFC, remove hydraulic pump/VSV servo (PN L44569Pxx) and turn into OEM, Woodward, for clean, inspection, returned to as new condition and final test per OEM standards and procedures.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of component IAW the US Navy LM2500 depot level technical manuals.

4.5 LM2500 SST GAS GENERATOR ACCESSORY UPGRADE CONFIGURATION AFTER OVERHAUL

All US Navy LM2500 SST gas generator MFC accessories shall be of the following configuration after overhaul:

All US Navy LM2500 SST gas generator DFC accessories shall be of the following configuration after overhaul:

All US Navy LM2500 SST gas generators shall have the mandatory Gas Turbine Technical Directives (TDs), GTBs/GTCs, listed in Table 2 with the exception of GTC 100R4 (optional work scope meeting discussion item) incorporated during the overhaul, if not previously incorporated. NSWCPD Code 423 will provide the upgrade kits to the Contractor to incorporate kits per Table 2 at no cost to the Contractor.

US Navy gas turbine kits shall only be requested if the kit is required for the overhaul. These kits shall be used for upgrading of the gas generator and accessories only. If the gas generator being overhauled previously had one of the TDs listed above incorporated, the kit for that TD shall not be requested. Determination of what kits are needed is the responsibility of the Contractor. The table/information that outline which kits are needed for the corresponding part numbers/serial numbers are found in the TD along with the detailed installation instructions. The most current information the Government has regarding which TDs are incorporated on the gas generator that arrives at the Contractor’s facility will be provided by NSWCPD Code 423 electronically via email. NSWCPD Code 423 will also provide electronically via email information regarding gas generator miscellaneous maintenance and operational log history.

All material required to complete the overhaul shall be identified in the DIR, prior to the work scope meeting. All material required to complete the overhaul shall be procured by the Contractor. The Contractor shall only use parts identified in the LM2500 Illustrated Parts Breakdown S9234-AD-MMO-070 through S9234-AD-MMO-090/LM2500.

4.6 TESTING REQUIREMENTS

After overhaul and assembly, the Contractor shall test the US Navy LM2500 SST gas generator assembly IAW the testing and the acceptance/rejection criteria cited in the latest revision of the appropriate US Navy LM2500 depot level technical manuals. The gas generator shall be tested to ensure that it will operate properly when installed shipboard. US Navy LM2500 SST gas generators shall be tested IAW the testing procedures outlined in Chapter 13 of the US Navy LM2500 technical manual S9234-AB-MMD-030/LM2500 latest revision. US Navy testing procedures require that the exhaust nozzle cold conical throat area measurement (AE8) is within 211 sq. in. +/- 1 sq. in.

The US Navy acknowledges that commercial vendors routinely correct test cell data to isometric conditions for the purpose of evaluating performance data. US Navy LM2500s must operate in high ambient conditions worldwide to support mission requirements. The US Navy rates its engines at 100 degree Fahrenheit conditions to ensure performance in all operating environments. If the Contractor’s exhaust nozzle cold conical throat area measurement is not 211 sq. in. +/- 1 sq. in. during performance testing, the performance data shall be corrected to the standard US Navy day (100 degree Fahrenheit ambient) and 211 sq. in. for data correction and extrapolation to the standard US Navy day IAW CDRL A005.

The gas generator shall be tested and performance data corrected to the standard US Navy day, ambient temperature of 100 degrees Fahrenheit and ambient pressure of 14.7 psia. The overhauled gas generator performance data, after corrected to a 100 degree Fahrenheit day, shall meet or exceed the criteria stated in the testing section of the US Navy LM2500 depot level technical manual.

4.7 ENGINEERING CHANGE PROPOSALS

The Contractor shall incorporate approved class I Engineering Change Proposals (ECPs) into US Navy LM2500 SST gas generators overhauled under this contract if: the approved ECP states that the change is to be incorporated into the gas generator upon return to the depot and the part(s) necessary for incorporation are available; or the approved ECP replaces a part or parts with another part or parts without retrofit recommendation, and the older part(s) is (are) no longer available as government furnished equipment or contractor furnished equipment. An ECP is considered approved if block 24A of the appropriate DD Form 1692 is checked and block 24C has been signed.

The ECPs listed in Table 3 below are required to be installed, unless found to be previously incorporated. Kits listed in Table 3 must be provided by the Contractor. Copies of the ECPs can be provided to the Contractor upon request from NSWCPD Code 423.

Table 3: Approved LM2500 ECPs (not provided as GFM, as needed)

5.0 REQUIREMENTS (LM2500 PBT GG, CLIN 0001)

5.1 GENERAL

The Contractor shall overhaul, modify, incorporate mandatory updates, maintain standard configuration integrity, assemble, test, preserve, package, document, mark and prepare for shipment the LM2500 PBT gas generator IAW this specification.

All overhaul work performed under this specification shall be IAW the current US Navy LM2500 depot level technical manuals, S9234-AB-MMD-010 through S9234-AB-MMD-060 latest revision, as applicable for the articles…