SOW_LM2500__(5_SOWs).pdf

Statement of Work #1

LM2500 HPC FWD CASE RUB COAT MACHINING

1.0 Scope: The Contractor shall provide services required to repair the LM2500 Marine Gas Generator

High Pressure Compressor Front Stator Case (HPCFSC). These services shall include delivery inspection, assembly of case halves, prepare to machine on vertical turret lathe (VTL), machine

HPCFSC abradable rub coat to predefined angles and dimensions supplied by FRCSW, locally blend as required, de-prep and clean, certify work performed, issue Certificate of Compliance, prepare for shipping and transportation, and other such technical processes as required by the service references.

2.0 References for Services:

2.1 S9234-AB-MMD-020/LM2500, U.S. Navy Technical Manual Gas Generator Overhaul and

Repair Instructions Depot Level Maintenance

2.2 Section 8.150 Repair of Compressor Front Stator Case Rub Coat

2.3 Section 10.9 Compressor Stator Horizontal Flange Bolts

2.4 General Electric (GE) authorized LM2500 Level 4 engine maintenance service provider

2.5 International Organization for Standardization (ISO) instructions 9001 and 14001

3.0 Delivery:

3.1 FRCSW POC shall arrange transportation of material.

3.2 Item 1: Compressor Front Stator Assembly, L24067G01-G21

3.3 Item 2: Compressor Front Stator Assembly, L25723G01-G03

3.4 Item 3: Compressor Front Stator Assembly, 9696M14G10-G27

3.5 Item 3: Compressor Front Stator Assembly, 9686M82G53-9686M82G56

3.6 FRCSW POC: Gary Rice, FRCSW Production Controller (619) 545-3636, gary.j.rice@navy.mil

3.7 Upon receipt of all parts the Contractor shall have 45 days to complete the repairs and contact

FRCSW POC to arrange transportation of the repaired components to FRCSW.

4.0 Requirement: The Contractor shall be a General Electric (GE) authorized LM2500 Level 4 engine maintenance service provider with a global license and have NCWCCD Philadelphia approval to meet

Navy requirements to provide the resources, outlined in the paragraph 1.0, for the repair of LM2500

HPCFSC. The stator cases halves shall be assembled from its shipping crate, use alignment fixtures to set-up case onto VTL, and machine (turn) the abradable rub coat to the predefined measurements designated by FRCSW. Fixtures and gages called out in References for Services 2.2, or comparable fixtures and gages as determined by FRCSW Engineering, are required by Contractor to ensure quality and conformity in accordance with Navy requirements. The FRCSW point of contact (POC) may visit the Contractor to view the HPCFSC and discuss the relationship of the HPCFSC during any period of the service.

4.1 In-process review: The contractor shall be prepared to discuss their progress during the period of performance after contract award, in letterform, E-mail or per phone call with FRCSW POC. The POC may request additional reports or site visits as required to review process, or to resolve any technical problems.

4.2 Reports: Upon completion and delivery of the HPCFSC, the contractor shall prepare and provide a

Certification of Compliance (COC) to all requirements specified in the Reference for Services. The

COC report shall list all dimensions with the actual dimensions in association with the tolerances included in the Reference for Services.

4.3 Inspection and Acceptance: The completed HPCFSC and all accompanied reports shall be inspected by FRCSW within ten days of delivery, or inspected on site by cognizant DCMA Americas if outside the contiguous United States (OCONUS) before delivery to FRCSW. The DCMA shall inform the contractor of any non-conforming elements of the HPCFSC and reports. FRCSW POC shall be contacted concerning DCMA and contractor technical issues. The contractor shall be responsible for any corrections to non-conforming print requirements and negotiating a new delivery schedule.

mailto:gary.j.rice@navy.mil

4.4 Contract Administration: Post award administration of any resultant purchase order shall be retained by FISCSD, Regional Contracts Department, Code 200. Through the process of the established repair process the Contractor determines that additional parts and or labor is required, the Contractor shall stop work and contact the Contracting Officer and FRCSW technical representative. The situation shall be discussed and if the Government determines that the additional parts and or labor are necessary the purchase order shall be modified. FRCSW personnel cannot authorize the Contractor to perform labor or furnish parts outside the scope of the order. A formal modification will need to be drafted per mutual agreement of the Contractor and Government.

Fleet Readiness Center Southwest

SOW#1

Certificate of Compliance

Repair of Compressor Front Stator Case.

Enter Repair Facility Name:

Enter Repair Facility Address:

Enter Part Name:

Enter Part Number:

Enter Part Serial Number:

1. Use bolting procedure outlined in U.S. Navy Technical Manual Stamp

2. Machine stages 1 through contour change of stage 7 abradable rub coat at an angle 2 degrees 56 minutes 40 seconds from case center-line.

Stamp

3. Measure diameters and print dimensional data. Stamp

4. Machine stages 7 through 11 parallel to center-line.

5. Measure diameters using FRCSW drop dimensions and print dimensional data. Stamp

Repair Facility Sign Date

6.

Statement of Work #2

LM2500 HPC AFT CASE RUB COAT MACHINING

1.1 Scope: The Contractor shall provide services required to repair the LM2500 Marine Gas Generator

High Pressure Compressor Rear Stator Case (HPCRSC). These services shall include delivery inspection, assembly of case halves, prepare to machine on vertical turret lathe (VTL), machine

HPCRSC abradable rub coat to predefined angles and dimensions supplied by FRCSW, locally blend as required, de-prep and clean, certify work performed, issue Certificate of Compliance, prepare for shipping and transportation, and other such technical processes as required by the service references.

2.6 References for Services:

2.7 S9234-AB-MMD-020/LM2500, U.S. Navy Technical Manual Gas Generator Overhaul and

Repair Instructions Depot Level Maintenance

2.8 Section 8.159 Repair of Compressor Rear Stator Case Rub Coat

2.9 Section 10.9 Compressor Stator Horizontal Flange Bolts

2.10 General Electric (GE) authorized LM2500 Level 4 engine maintenance service provider

2.11 International Organization for Standardization (ISO) instructions 9001 and 14001

3.8 Delivery:

3.9 FRCSW POC shall arrange transportation of material.

3.10 Item 1: Compressor Rear Stator Assembly, 9686M83G16- G18

3.11 Item 2: Compressor Rear Stator Assembly, 9686M81G03- G09

3.12 FRCSW POC: Gary Rice, FRCSW Production Controller (619) 545-3636, gary.j.rice@navy.mil

3.13 Upon receipt of all parts the Contractor shall have 45 days to complete the repairs and contact

4.5 Requirement: The Contractor shall be a General Electric (GE) authorized LM2500 Level 4 engine

Navy requirements to provide the resources, outlined in the paragraph 1.0, for the repair of LM2500

Rear Stator Case. The stator cases halves shall be assembled from its shipping crate, use alignment fixtures to set-up case onto VTL, and machine (turn) the abradable rub coat to the predefined measurements designated by FRCSW. Fixtures and gages called out in References for Services 2.2, or comparable fixtures and gages as determined by FRCSW Engineering, are required by Contractor to ensure quality and conformity in accordance with Navy requirements. The FRCSW point of contact

(POC) may visit the Contractor to view the HPCRSC and discuss the relationship of the HPCRSC during any period of the service.

4.6 In-process review: The contractor shall be prepared to discuss their progress during the period of may request additional reports or site visits as required to review process, or to resolve any technical

4.7 Reports: Upon completion and delivery of the HPCRSC, the contractor shall prepare and issue a

4.8 Inspection and Acceptance: The completed HPCRSC and all accompanied reports shall be inspected by FRCSW within ten days of delivery, or inspected on site by cognizant DCMA Americas if outside the contiguous United States (OCONUS) before delivery to FRCSW. The DCMA shall inform the contractor of any non-conforming elements of the HPCRSC and reports. FRCSW POC shall be contacted concerning DCMA and contractor technical issues. The contractor shall be responsible for

4.9 Contract Administration: Post award administration of any resultant purchase order shall be retained process the Contractor determines that additional parts and or labor is required, the Contractor shall stop work and contact the Contracting Officer and FRCSW technical representative. The situation shall be discussed and if the Government determines that the additional parts and or labor are necessary the purchase order shall be modified. FRCSW personnel cannot authorize the Contractor to perform labor

SOW#2

Repair of Compressor Rear Stator Case.

7. Use bolting procedure outlined in U.S. Navy Technical Manual. Stamp

8. Machine stages 12-14 abradable rub coat perpendicular to VTL table. Stamp

9. Measure diameters and print dimensional data. Stamp

10. Machine stages 15 and 16 abradable rub coat at an angle 2 degrees 50 minutes from perpendicular to

VTL table.

11. Measure diameters using FRCSW drop dimensions and print dimensional data.

Statement of Work #3

LM2500 HPC STATOR CASE VANE TIP GRINDING

1.2 Scope: The Contractor shall provide services required to premeasure and vane tip grind the LM2500

Marine Gas Generator High Pressure Compressor Stator Case (HPCSC). These services shall include, delivery inspection, preparing case lands for measure, measuring case lands for FRCSW ‘match grind’ requirement, providing land measurement data in Microsoft Excel format (minimum, maximum and average radius), preparing vanes for grinding (snubbing), pregrind inspect stator case (masking), vane tip-grind to ‘match grind’ requirements, providing vane measurement data in Microsoft Excel format

(minimum, maximum and average radius), deburring, cleaning, and other such technical processes as required by the service references.

2.12 References for Services:

2.13 S9234-AB-MMD-030/LM2500, U.S. Navy Technical Manual Gas Generator Overhaul and

Repair Instructions Depot Level Maintenance

2.14 Section 9.42 MKIII Compressor Stator Pregrind Inspection and Vane Tip Grinding of

Compressor Stator Vanes

2.15 Section 9.43 Alternate Procedure for Vane Tip Grind- Compressor Front Stator

2.16 Section 9.44 Alternate Procedure for Vane Tip Grind- Compressor Rear Stator

2.17 General Electric (GE) authorized LM2500 Level 4 engine maintenance service provider

2.18 International Organization for Standardization (ISO) instructions 9001 and 14001

3.14 Delivery:

3.15 FRCSW POC shall arrange transportation of material.

3.16 Item 1: Compressor Front Stator Assembly; L24067G01-G21

3.17 Item 2: Compressor Front Stator Assembly, L25723G01- G03

3.18 Item 3: Compressor Front Stator Assembly, 9696M14G10-G27

3.19 Item 4: Compressor Front Stator Assembly; 9686M82G53-G56

3.20 Item 5: Compressor Rear Stator Assembly; 9686M83G16- G18

3.21 Item 6: Compressor Rear Stator Assembly, 9686M81G03- G09

3.22 Item 7: Assorted Compressor Stator Assembly Hardware: Shrouds, vanes, levers, bolts, nuts, washers, etc.

3.23 FRCSW POC: Gary Rice, FRCSW Production Controller (619) 545-3636, gary.j.rice@navy.mil

3.24 Upon receipt of all parts the Contractor shall have 45 days to complete the repairs and contact

4.10 Requirement: The Contractor shall be a General Electric (GE) authorized LM2500 Level 4 engine

Navy requirements to provide the resources, outlined in the paragraph 1.0, for the premeasure and vane tip grind of LM2500 HPCSC. The HPCSC shall be assembled from its shipping crate with FRCSW supplied hardware as described in 2.2 References for Services 9.42 or alternate procedure described in

2.4 References for Services 9.44. The HPCSC shall be premeasured and vane tip ground as described in 2.2 References for Services 9.42 or alternate procedures described in 2.3- 2.4 References for

Services 9.43-9.44. Fixtures, tooling, and gages called out in References for Services 2.2- 2.4, or comparable fixtures and gages as determined by FRCSW Engineering, are required by Contractor to ensure quality and conformity in accordance with Navy requirements. The FRCSW point of contact

(POC) may visit the Contractor to view the stator case and discuss the relationship of the stator case

4.11 In-process review: The contractor shall be prepared to discuss their progress during the period of may request additional reports or site visits as required to review process, or to resolve any technical

4.12 Reports: Upon completion and delivery of the stator case, the contractor shall prepare and provide a

4.13 Inspection and Acceptance: The completed stator case and all accompanied reports shall be inspected by cognizant DCMA Americas on site before delivery to FRCSW. The DCMA shall inform the contractor of any non-conforming elements of the stator case and reports. FRCSW POC shall be

4.14 Contract Administration: Post award administration of any resultant purchase order shall be retained process the Contractor determines that additional parts and or labor is required, the Contractor shall stop work and contact the Contracting Officer and FRCSW technical representative. The situation shall be discussed and if the Government determines that the additional parts and or labor are necessary the purchase order shall be modified. FRCSW personnel cannot authorize the Contractor to perform labor

SOW#3

Compressor Stator Case Pre-measure and Vane Tip Grind

12. Obtain required vane tip angle for grinding stages 3-6. Stamp

13. Measure HPCS case lands radii using drop dimensions. Stamp

14. Print dimensional data (Minimum, Maximum, and Average). Stamp

15. Measure stator case stages 3-9 vanes radii using drop dimensions. Stamp

16. Grind vanes to ‘match grind’ dimensions. Stamp

17. Measure stator case stages 3-9 vanes radii using drop dimensions. Stamp

18. Print final dimensional data (Minimum, Maximum, and Average). Stamp

Statement of Work #4

LM2500 HPC 3-9 SPOOL RUB COAT GRINDING

1.3 Scope: The Contractor shall provide services required to repair the LM2500 Marine Gas Generator

High Pressure Compressor Rotor Stages 3-9 spool. These services shall include delivery inspection, vertical turret lathe (VTL) setup for machining (turning) the seven (7 ea.) abradable rub coated lands, turning the lands with dimensions provided by FRCSW (finish shall be 125 micro inches), locally blend as required, de-prep and clean, certify work performed, issue Certificate of Compliance, prepare for shipping and transportation, and other such technical processes as required by the service references.

2.19 References for Services:

2.20 S9234-AB-MMD-020/LM2500, U.S. Navy Technical Manual Gas Generator Overhaul and

Repair Instructions Depot Level Maintenance

2.21 Section 8.217, Repair of Stage 3-9 Spool Abradable Rub Coat

2.22 General Electric (GE) authorized LM2500 Level 4 engine maintenance service provider

2.23 International Organization for Standardization (ISO) instructions 9001 and 14001

3.25 Delivery:

3.26 FRCSW POC shall arrange transportation of material.

3.27 Part number: 9021M64P07-P11

3.28 FRCSW POC: Gary Rice, FRCSW Production Controller (619) 545-3636, gary.j.rice@navy.mil

3.29 Upon receipt of all parts the Contractor shall have 45 days to complete the repairs and contact

4.15 Requirement: The Contractor shall be a General Electric (GE) authorized LM2500 Level 4 engine

Navy requirements to provide the resources, outlined in the paragraph 1.0, for the repair of LM2500 compressor rotor stages 3-9 spool. The stages 3-9 spool abradable rub coat shall be machined (turned) as described in References for Services 2.2. Fixtures and gages called out in References for Services

2.2, or comparable fixtures and gages as determined by FRCSW engineering, are required by

Contractor to ensure quality and conformity in accordance with Navy requirements. The FRCSW point of contact (POC) may visit the Contractor to view the compressor rotor stages 3-9 spool and discuss the relationship of the compressor rotor stages 3-9 spool during any period of the service.

4.16 In-process review: The Contractor shall be prepared to discuss their progress during the period of may request additional reports or site visits as required to review process, or to resolve any technical

4.17 Reports: Upon completion and delivery of the compressor rotor stages 3-9 spool, the Contractor shall prepare and issue a Certification of Compliance (COC) to all requirements specified in the Reference for Services. The COC report shall list all dimensions with the actual dimensions in association with the tolerances included in the Reference for Services.

4.18 Inspection and Acceptance: The completed compressor rotor stages 3-9 spool and all accompanied reports shall be inspected by FRCSW within ten days of delivery, or inspected on site by cognizant

DCMA Americas if outside the contiguous United States (OCONUS) before delivery to FRCSW. The

DCMA shall inform the Contractor of any non-conforming elements of the compressor rotor stages 3-9 spool and reports. The POC shall issue letter of acceptance to the Contractor within ten days of the end of the inspection period. FRCSW POC shall be contacted concerning DCMA and Contractor technical issues. The Contractor shall be responsible for any corrections to non-conforming print requirements and negotiating a new delivery schedule.

4.19 Contract Administration: Post award administration of any resultant purchase order shall be retained process the Contractor determines that additional parts and or labor is required, the Contractor shall stop work and contact the Contracting Officer and FRCSW technical representative. The situation shall be discussed and if the Government determines that the additional parts and or labor is necessary the purchase order shall be modified. FRCSW personnel cannot authorize the Contractor to perform labor

SOW#4

Repair of compressor rotor stages stage 3-9 spool.

19. Machine lands stages 3 and 4, between drop dimensions from rear flange surface 14.943” to 20.165”, respectively diameters 19.191 – 19.199 to 17.467 – 17.475 and angle 9° 22’24”.

20. Machine lands stage 5, between drop dimensions from rear flange surface 11.8085” to 14.943”, respectively diameters 20.035” – 20.043” to 19.191” – 19.199” and angle 7° 40’04”.

21. Machine lands stages 6 and 7, between drop dimensions from rear flange surface 5.000” to 11.8085”, respectively diameters 21.485” – 21.493” to 20.035” – 20.043” and angle 6° 4’42”. Stamp

22. Machine lands stages 8 and 9, between drop dimensions from rear flange surface 0.5565”” to 5.000”, respectively diameters 22.379” – 22.387” to 21.485” – 21.493” and angle 5° 44’41”. Stamp

23. Inspect and clean Stamp

Statement of Work #5

LM2500 HPT S2 NOZZLE SUPPORT GRINDING S1 &S2 SHROUDS

1.4 Scope: The Contractor shall provide services required to repair both configurations of high pressure turbine nozzle (HPTN) shrouds stage1, shrouds stage 2 and interstage seals. (i.e. single shank and twin shank configurations) The HPTN repair encompasses dry machining of the shrouds for stages1 and 2 plus dry grinding of the interstage seals. The shrouds grind dimensions are dependent upon maximum radii of high pressure turbine rotor (HPTR) blades, which will be supplied; the HPTR and HPTN shall be identified and maintained as a matched set upon completion of nozzle shroud grind operation. These services shall include, delivery inspection, receipt of maximum HPTR radii dimensions, preparing

HPTN for measure and grind, deburring, cleaning, providing certificate of compliance (COC) and other such technical processes as required by the service references.

2.24 References for Services:

2.25 S9234-AB-MMD-030/LM2500, U.S. Navy Technical Manual Gas Generator Overhaul and

Repair Instructions Depot Level Maintenance

2.26 Section 9.73 Set-up for Grinding of Stage 2 High Pressure Turbine Nozzle Assembly.

2.27 Section 9.74 Grinding of High Pressure Turbine Nozzle Interstage Seal (Twin Shank

Turbine Configuration).

2.28 Section 9.75 Grinding of High Pressure Turbine Nozzle Interstage Seal (Single Shank

Turbine Configuration).

2.29 Section 9.76 Machining and Grinding of High Pressure Turbine Nozzle Stage 1

Shrouds.

2.30 Section 9.77 Grinding of High Pressure Turbine Nozzle Stage 2 Shrouds.

2.31 General Electric (GE) authorized LM2500 Level 4 engine maintenance service provider

2.32 International Organization for Standardization (ISO) instructions 9001 and 14001

3.30 Delivery:

3.31 FRCSW POC shall arrange transportation of material.

3.32 Item 1: HPT Stage 2 Nozzle Assembly (Twin Shank); L21722G01- G09

3.33 Item 2: HPT Stage 2 Nozzle Assembly (Single Shank); L25739G05- G23

3.34 FRCSW POC: Gary Rice, FRCSW Production Controller (619) 545-3636, gary.j.rice@navy.mil

3.35 Upon receipt of all parts the Contractor shall have 45 days to complete the repairs and contact

4.20 Requirement: The Contractor shall be a General Electric (GE) authorized LM2500 Level 4 engine

Navy requirements to provide the resources, outlined in the paragraph 1.0, for the repair of the high pressure turbine nozzle assembly. The HPTN shall be removed from its shipping crate. The HPTN will be prepared using the materials, fixtures, tooling, and gages as called out in References for Services

2.2- 2.6, or comparable fixtures and gages as determined by FRCSW Engineering. This will ensure quality and conformity by the Contractor in accordance with Navy requirements. The FRCSW point of contact (POC) may visit the Contractor to view the nozzle and discuss the relationship of the nozzle

4.21 In-process review: The contractor shall be prepared to discuss their progress during the period of may request additional reports or site visits as required to review process, or to resolve any technical

4.22 Reports: Upon completion and delivery of the stator case, the contractor shall prepare and provide a

4.23 Inspection and Acceptance: The completed stator case and all accompanied reports shall be inspected by cognizant DCMA Americas on site before delivery to FRCSW. The DCMA shall inform the contractor of any non-conforming elements of the stator case and reports. FRCSW POC shall be

4.24 Contract Administration: Post award administration of any resultant purchase order shall be retained process the Contractor determines that additional parts and or labor is required, the Contractor shall stop work and contact the Contracting Officer and FRCSW technical representative. The situation shall be discussed and if the Government determines that the additional parts and or labor are necessary the purchase order shall be modified. FRCSW personnel cannot authorize the Contractor to perform labor

SOW#5

High Pressure Turbine Nozzle

Enter HPTN Number:

Enter HPTN Serial Number:

Enter Matching HPTR Serial Number:

24. Obtain required shroud stage 1 dimension. Stamp

25. Obtain required shroud stage 2 dimension. Stamp

26. Grind Forward Edge of Nozzle Lip Seal. Stamp

27. Grind Interstage Seal Steps. Stamp

28. Grind Interstage Seal Axially and Radially. Stamp

29. Grind Interstage Seal Grooves. Stamp

30. Deburr through use of file, wire brush, and emery cloth. Stamp

31. Machine and Grind Shrouds Stage 1. Stamp

32. Machine and Grind Shrouds Stage 2. Stamp

33. Record Dimensional Measurements from Table 9-22. Stamp