SOW_for_501-K34_repairs.docx

501-K34 STATEMENT OF WORK for ASP-1748, 1938, 1361, 1851, 2246 and 1848 The Contractor shall induct the engine, upload engine location to WEBLOG, verify GGTB 11 inventory sheet, disassemble, inspect, photograph any discrepancies or abnormalities, and analyze the engine assembly container/canister, accessories, assemblies, subassemblies, and components.

(1) Within three (3) business days of receipt of equipment to be repaired, as visual inspection shall be done and the Contractor shall provide the engine/module serial numbers to NSWC-PD, Code 423/424. If the items are received in unauthorized/non-reusable containers, communicate this fact to NSWC-PD, Code 423/424 and await instructions.

(2) The Contractor shall disassemble, inspect and test as necessary (to detect damaged parts) each gas turbine engine/module assembly, container/canister accessories, assemblies, subassemblies, and components, and prepare a pre-inspection proposal listing all parts/components requiring repair or replacement. All inspection and repair/replace criteria, procedures, and modifications shall be in accordance with established Original Engine Manufacturer (OEM) practices and appropriate Technical Directives (i.e., Gas Turbine Bulletin (GTB), Gas Turbine Change (GTC), and Minimum Inspection Maintenance Requirements (MIMR), that have been determined acceptable by NSWC-PD, Code 423/424 and/or the Appropriate Depot Technical manuals.

(3) The on-site Government representative and/or NSWC-PD, Code 423/424 shall have the authority to require further disassembly or more extensive failure analysis of all or part of any parts/assemblies. In addition, the Contractor shall advise NSWC-PD, Code 423/424 by telephone if an extensive engineering analysis is required and the reason for it. If NSWC-PD, Code 423/424 authorized the Contractor to conduct an extensive engineering analysis, such authorization shall be confirmed in writing and pre-inspection proposal revised as necessary.

The Contractor shall repair, replace, modify, assemble, test, preserve, package, mark and prepare for shipment each gas turbine engine/module assembly, container/canister accessories, assemblies, subassemblies, and components.

(1) The Contractor is authorized to apply AEP coating, as required.

(2) The Contractor is authorized to use applicable 501-K34 technical manuals to perform common repairs.

(3) Authorized replacement material shall be OEM, DLA, or Navy approved new or serviceable parts. All exchange and/or serviceable material shall be in overhauled condition, Traceability of serviceable and overhauled components is not required as long as the finished component meets OEM overhaul standards.

(4) NAVSEA is aware and agrees that when removed/repairable components are exchanged for a serviceable component, the core material becomes the property of the contractor.

(5) Material removed from Navy Decommissioned Assets is the property of the US Navy and shall be placed in Government property storage. This material may be used on any engine/module inducted for repair under this contract, and may reduce the cost of any fixed price proposal submission.

501-K34 ENGINE MINIMUM INSPECTION/REPAIR REQUIREMENTS

GENERAL REQUIREMENTS

(1) The following defines the minimum inspection and repair effort for the 501-K34 engine. The contractor shall develop the balance of the work requirement for each repairable from the complete work control document package based on analysis of the problem(s) identified and in consonance with the concept of "on condition" maintenance. All engine work will be repair of the existing condition plus other repairs necessary to allow the engine to operate 15,000 hours after installation on a naval ship.

(2) The contractor shall be guided by the S9311-CW-TRS-010, -020, -030, and - 040 suite of manuals. All OEM and NSWC-PD approved repair procedures will be allowed. Any Contractor repair procedures, if approved by NSWC-PD/NAVSUP-WSS, will be allowed. The OEM Spare Parts Application Data List (SPADL) may be used as well as the Illustrated Parts Breakdown (IPB).

(3) NAVSEA technical directives shall be incorporated as directed by the General Gas Turbine Bulletin No. 0, latest revision. The Contractor is authorized to use all engineering change authorizations approved by the Navy.

501-K34 ENGINE REQUIREMENTS

(1) Engine

a. Inspect exterior as to the general condition of the following:

i. Accessory mounting.

ii. Hoses, electrical harness, leads, cables, connectors.

iii. Replace all igniters with new.

iv. All fuel, oil and air hoses for kinks, chafing, etc.

v. Rear engine mount bracket and plate.

b. The Contractor shall replace all bearings during a 501-K34 Engine repair with new bearings.

(2) Accessory Gear Box Assembly

a. Inspect the accessory gearbox components. Comply With applicable bulletins and replace all bearings with new.

(3) Compressor

a. Open compressor case and visually inspect rotor blades and stators as an assembly.

b. Inspect inlet housing and re-coat if coating is missing or corrosion is evident.

c. Inspect compressor case exterior for coating loss and/or corrosion attack.

d. Recoat with Sermetel Coating or equivalent, 1st thru 5th Stage Compressor Blades & Wheels. Custom 450 Compressor Wheels will remain uncoated.

(4) Combustor

a. Remove and disassemble the split outer combustion casing, clean splitline flange surfaces and re-seal.

b. Remove combustion liners and inspect.

(5) Turbine

a. Inspect first stage vanes for corrosion and blade track deterioration.

b. Rotors with operating hours in excess of 5,000 operating hours must be disassembled to FPI and Heat tint 1st, 2nd and 3rd stage blades and to clean internal cooling air passages of wheels.

c. Remaining blades and vanes to be inspected.

d. Inspect rear bearing support.

(6) Accessory Components

a. Electrical System

i. Test and inspect all thermocouples.

ii. Test and inspect thermocouple harnesses and T-block.

iii. Replace all igniters with new, Engine/module testing to accomplish functional test.

b. Lube System

i. Inspect lube system magnetic plug for metal particles and test electrical resistance across magnetic poles.

ii. Inspect lube oil filter and renew element.

iii. Inspect external scavenge pump and main oil pump Engine/module testing to accomplish functional test.

c. Fuel System

i. Clean and inspect burner drain valves.

ii. Clean and inspect high pressure filter.

iii. Clean and inspect low pressure filter.

iv. Clean, inspect and test fuel nozzles.

v. Inspect CIT sensor.

vi. Inspect fuel pump. Replace carbon seals and diaphragm. Engine/module testing to accomplish functional test.

d. Air Bleed System

i. Clean and inspect compressor air bleed filter.

ii. Replace seals and rings in the 5th and 10th stage bleed air valves.

iii.

(7) Engine Shipping Container

a. Inspect interior and exterior for damage, corrosion, cleanliness, inclusion of hardware, etc. Replace all gaskets and seals with new. Verify that proper engine mounting slotted bracket (Part No. 3-13869 for shipping container PN 6877158) to be used. If wrong bracket is used in container, contractor shall replace with the correct one. Proper bracket (Cage Code 94231, Part No. 3-13869) may be requested as GFM from NSWC-PD, Code 423 via the Contracting Officer. Repair as required. Navy may supply replacement shipping container if contractor repair cost exceeds 70% of the cost of a new shipping container.