N64498-16-R-5015_Amendment_2.pdf

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15A. NAME AND TITLE OF SIGNER (Type or print)

30-105-04EXCEPTION TO SF 30

APPROVED BY OIRM 11-84

STANDARD FORM 30 (Rev. 10-83) Prescribed by GSA

FAR (48 CFR) 53.243

The purpose of this amendment is to (1) provide questions and answ ers submitted in response to the subject procurement and (2) extend the closing date from 31 January 2017 to 03 February 2017.

All other terms and conditions remain unchanged.

See page 2.

1. CONTRACT ID CODE PAGE OF PAGES

J 1 23

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

16C. DATE SIGNED

BY 19-Jan-2017

16B. UNITED STATES OF AMERICA15C. DATE SIGNED15B. CONTRACTOR/OFFEROR

(Signature of Contracting Officer)(Signature of person authorized to sign)

8. NAME AND ADDRESS OF CONTRACTOR (No., Street, County, State and Zip Code) X N64498-16-R-5015

X 9B. DATED (SEE ITEM 11)

09-Dec-2016

10B. DATED (SEE ITEM 13)

9A. AMENDMENT OF SOLICITATION NO.

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

X The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offer X is extended, is not extended.

Offer must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended by one of the following methods:

(a) By completing Items 8 and 15, and returning copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

or (c) By separate letter or telegram which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN

REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by telegram or letter, provided each telegram or letter makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

12. ACCOUNTING AND APPROPRIATION DATA (If required)

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NO. AS DESCRIBED IN ITEM 14.

A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE

CONTRACT ORDER NO. IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation date, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(B).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

E. IMPORTANT: Contractor is not, is required to sign this document and return copies to the issuing office.

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

10A. MOD. OF CONTRACT/ORDER NO.

2. AMENDMENT/MODIFICATION NO. 5. PROJECT NO.(If applicable)

6. ISSUED BY

3. EFFECTIVE DATE

19-Jan-2017

CODE

NAVAL SURFACE WARFARE CENTER PHILA

CODE 02221, ASHLEY GAYLE

215-897-7604, ASHLEY.GAYLE@NAVY.MIL

5001 SOUTH BROAD STREET

PHILADELPHIA PA 19112

N64498 7. ADMINISTERED BY (If other than item 6)

4. REQUISITION/PURCHASE REQ. NO.

CODE

See Item 6

FACILITY CODECODE

EMAIL:TEL:

N64498-16-R-5015

SECTION SF 30 BLOCK 14 CONTINUATION PAGE

SUMMARY OF CHANGES

SECTION SF 30 - BLOCK 14 CONTINUATION PAGE

The following have been added by full text:

AMENDMENT 0002

PART I

The following changes have been made:

1. For the initial task order award(s) the offerors will be evaluated on a Low Cost Technically Acceptable (LPTA) basis to determine which offeror will receive award of any quantity above the guaranteed minimum (if applicable). All subsequent orders will be evaluated using the criteria listed in Section H of the RFP.

2. Section F has been extended from 180 days to 200 days .

3. The closing date of this RFP has been extended from 31 January 2017 to 03 February

2017.

PART II

This amendment provides a list of questions and comments received in response to the solicitation. The questions and comments are provided for all potential Offerors to review. Note that questions may have been edited for clarity and duplicative questions may have been combined or deleted. All available, necessary information and any necessary changes to the solicitation resulting from consideration of the below questions and comments have been incorporated into the solicitation in PART I of this Amendment.

Q1. Could US Navy provides list of the ESN of GG the overhauled and related service Bulletin status?

A1: ESNs are not defined at this time. Navy will provide ESN, service bulletin status and configuration status at time of engine induction. Navy does not know at this time exactly what ESNs will be repaired under this contract.

Q2. Ref. C.3.5.1 Compressor Front Frame Assembly step e:

Instead of replace the original Phenalic seal removed with the METCO 601 configuration, can be the original seal upgraded/repaired to the METCO 601 seal, as per GE technical instructions?

A2: Yes, however per Section C.3.7 of the SOW, the contractor will still need to request permission and provide copy of GE technical instruction to officially approve deviation.

Q3. Ref. C.3.5.7 High Pressure Turbine Stage 1 Nozzle Assembly:

Please provides coating to be apply to the reworked nozzles or of new provided

A3: Reworked nozzles should be PtAl coated. Newly provided OEM nozzles, if necessary, should be BC22 coated.

Q4. Ref. C.3.5.8 High Pressure Turbine Stage 2 Nozzle Assembly

Please provides coating to be apply to the reworked nozzles or of new provided

A4: Reworked nozzles should be PtAl coated. Newly provided OEM nozzles, if necessary, should be BC22 coated.

Q5. Ref. C.3.5.9 High Pressure Turbine Rotor Assembly

Please provides coating to be apply to the reworked blades or of new provided

A5: Reworked HPT stage 1 and 2 blades should be PtAl coated. Newly provided OEM HPT stage 1 and 2 blades, if necessary, should be BC22 coated.

Q6. Repair activities about the shipping container will be considered out of work scope/supply and quoted on top to the fixed price: is this in line with US Navy expectations?

A6. Navy anticipates having the engines in a ready state shipping container at time of contract award. Contractor(s) are responsible for shipping the engines from Philadelphia, PA to their faciltiy and back to Philadelphia, PA for delivery. Contractor(s) assume responsibility during their time of possession of the engine and shipping container.

Q7.Could US Navy, provide all GTCs and upgrade documents in advance in order to properly quote it’s introduction?

A7. By request the Navy can provide GTCs and upgrade documents (“zero bulletin”) containing approved technical directives to all bidders in advance. Should be noted that applicability of each technical directive for a given ESN will not be defined until point of induction/inspection.

Q8. The provided firm fix price should cover activities conducted on engines in normal tear and ware conditions. Any other occurrence such as scrap of major frames (Compressor Front frame structure, Forward Compressor Stator case, Rearward Compressor Stator case, Compressor Rear Frame structure, Turbine Mid Frame Structure) will be considered as over and above to the Fixed price. Moreover any abnormal scrap of high value parts (such as but not limited to: Disk stg 1 compressor rotor, Disk stg 2 compressor rotor, Spool 3-9 compressor rotor, spool 11-13 compressor rotor, spool 14-16 compressor rotor, HPTR forward shaft, Disk stg 1 & 2 HPT, HPTR rear shaft, Oil pump, Fuel pump, Main fuel control) due to not proper engine operation (over speed, over temperature, wrong storage) should be considered as over and above to the fixed price: is this acceptable to US Navy?

A8. Offerors should not anticipate scrap of major components in their firm fixed price quote.

Following inspection, if a major component is found to be beyond published serviceable limits requiring replacement with new, the associated CLIN for that major component included in the Offeror’s quote will be executed via modification.

Q9. In case of parts that due to old standard will generate the need for scrap not related to part wear/damage, this will be considered as over and above to the fixed price: is this acceptable to US Navy?

A9. Navy engines provided under this contract are of older configuration. It is not the Navy’s intention to replace (scrap) older configuration parts that are repairable/serviceable with new parts. Parts should only be considered scrap if they exceed published service limits.

Q10. In case of old standard parts no more procurable superseded by parts not reported in US Navy IPB S9234-AD-MMO-070, would it be possible to use OEM IPB GEK 50504 to assess the interchangeability between procurable part and removed part? In any case any installed part not reported in US Navy IPB will be notified to US Navy.

A10. NSWCPD: Navy will consider on a case-by-case basis deviations from Navy manuals per Section C.3.7 of the SOW . Vendor can request alternate procedures and parts in writing for Navy review and approval.

Q11. For HPT Stg 1 and stg 2 blades, HPT stg. 1 nozzles and HPT stg. 2 nozzles, will consider in the quotation the systematic replacement of 100% of such parts at disassembly: is this acceptable to US Navy?

A11. No, this is not acceptable. Navy SOW specifically states that parts are to be repaired.

Replacement of parts with new shall only be considered if parts are not repairable and exceed published service limits.

Q12. With reference to the Item 0030 OVER AND ABOVE, pag.13, taking into account that the O&A amount is unforeseen, so it cannot be determined in advance, if strictly required can provide the average O&A cost incurred on the previous 6 engines overhauled at Do we have to provide that?

A12. NSWCPD: No, contractors are requested to develop firm fixed price for Section C of the contract without projecting over and above costs.

Q13. With reference to page 19, C.3.4.1: are the parts listed in Tab.2 (pag. 21), not provided as GFE, to be included in the Firm and Fixed Price quote or shall be quoted separately?

A13. Yes, the Navy suggests material to support incorporation of GTCs listed in Table 2 be included in firm fixed pricing.

Q14. With reference to page 22, C.3.5: Depot TAT performance will be measured at net of the hold time between the DIR Report official issuing to US Navy and the engine rebuild start date as approved by US Navy. Is that acceptable?

A14. As Section F states on Page 40 of the RFP “ For each awarded task order first unit due 200 days after date of order. 30 days thereafter for each additional engine.

Q15. Clause C.3.4. please clarify what does mean the following sentence “The use of aftermarket parts is not permitted.” Please advise;

1.1 In any case will use only OEM parts;

1.2 Is permitted, in alternative of new OEM genuine parts, the use of OEM overhauled parts? Please advise;

A15. The use of aftermarket parts is not permitted and requires OEM parts to be used during the overhaul. Use of overhauled OEM parts will be permitted on a case-by-case basis.

Q16. Section F. “Delivery information” has to be intended that after contract award US Navy will ship to the contractor one GG each 30 days?

A16. Delivery under the resultant Contract(s) shall be FOB Destination, Philadelphia, PA. If an Offeror were to receive an award for two (2) overhauls, both engines would be picked up by the Contractor (in Philadelphia) and then the first delivery back to the Government of the completed overhauled engine shall be 180 days after date of order and then the second overhauled engine would be due to the Government 30 days thereafter (210 days after date of order).

Q17. Section F. Is 180 days after task order award the required TAT ? 3.1 if yes as per above point 3. GE Avio respectfully suggests that the 180 day delivery period (transportation and overhaul turnaround time) begin with the transfer of each individual gas generator from US Navy possession to contractor. The delivery start date will be contractor receipt of a gas generator at the mutually agreed CONUS location (along with complete export documentation). The delivery period shall end upon completion of the US Navy borescope inspection after the acceptance test run at contractor plant.

A17. Navy concurs.

Q18. Gas Generators and Power Turbine Transport. 4.1 It is right understood that all what concern the engines pick-up and shipment from US Navy location to selected contractor depot site is at contractor cost and responsibility?

A18. Navy concurs.

Q19. It is right understood that all what concern the engines shipment back to the US Navy location will entirely at US Navy cost and responsibility?

A19. Shipment back to US Navy location (Philadelphia) cost and responsibility resides with the vendor and should be included in the vendor’s firm fixed price submittal.

Q20. Manuals. It is right understood that US Navy will provide to the selected contractor the manuals applicable to the execution of the required work scope only when will be issued the PO/Contrac to the selected contractor?

A20. Yes, the documents will be provided at the time of award but no later than 3 weeks.

Q21. Please clarify for item 0026 for N64498-16-R-5099 supplies/Services which quotation has to be provided ?

A21. CLIN 0032 is Not Separately Priced, Offerors shall not provide a price for this line item.

Q22. Section F - Deliveries or Performance: First unit due 180 days after date of order: what if the engine is not made available for pick-up at the order date? Should we consider the pick-up date in that case?

A22. Navy anticipates having engines available at the contract award date.

Q23. Is there any list of excusable delays (which might affect the TAT performance) such as long lead time repairs or long lead time procurable items (e.g, cases, frames, parts with defects beyond normal wear, etc.)

A23. Navy does not anticipate major components scrapping out. If major components are found to be scrap, time required to obtain replacement material would not be counted against delivery schedule.

Q24. Page 13 of the solicitation, item No 30 is a line item for “over and above” work. What are you expecting to see in the proposed pricing for this item? Possibly an hourly rate for labor?

Should it remain “blank” with an understanding that the final price after the tear down of the GG and the agreed upon workscope is complete will change? Please explain.

A24. The over and above CLIN 0030 allows for post teardown work scope negotiations for any unforeseen repair or material needs that is not covered under CLINs 0003-0029.

Q25. Page 13 of the solicitation, Item No 32 - Please explain if you are expecting a price for this line item.

A25.CLIN 0032 is Not Separately Priced, Offerors shall not provide a price for this line item.

Q26. Do we need to be registered in the “System for Award Management” (SAM) prior to submitting our proposals ?

A26. Contractors must be registered in the “System for Award Management” prior to award. If the contractor is not registered by this time, the government reserves the right to award to an offeror who is currently registered in the “System for Award Management” database.

Q27. I understand that the transportation cost to move the GG to Philadelphia (after overhaul) is to be included in our pricing. Will the US government deliver the GG to our Level 4 depot facility in Germany? Do we need to include a transportation cost to move the GG from a specific location to our Level 4 depot in Germany?

A.27 Yes, The contractor is responsible for shipping to and from our Philadelphia, PA destination.

Q28. Our expectation and understanding is that if a contract is awarded , the final pricing of an overhaul will not be agreed upon until after the tear down of the GG and final workscope is approved by the US government representative. Is this correct?

A28. No, this is a firm fixed price contract. The contractor is to propose pricing for the GG overhaul for CLINs 0001-0002. If a major component is found to be beyond published serviceable limits requiring replacement with new, the associated CLINs (0003 – 0031) for that major component included in the vendor’s quote will be executed as part of a contract modification during the term of the contract.

Q29. Can our proposal be submitted electronically? Perhaps with follow up copies of the documents?

A29. Yes, proposals may be submitted both electronically and by mail.

SECTION A - SOLICITATION/CONTRACT FORM

The required response date/time has changed from 31-Jan-2017 03:00 PM to 03-Feb-2017 03:00 PM.

SECTION B - SUPPLIES OR SERVICES AND PRICES

The following have been modified:

NOTES TO SECTION B

1. CONTRACT TYPE: The Naval Surface Warfare Center, Philadelphia Division (NSWCPD) located in Philadelphia, PA proposes to award one or more Indefinite-Delivery, Indefinite-Quantity, Firm-Fixed-Price type Contract(s) providing support services and associated parts as described in Section C, Statement of Work. The Contract(s) shall have an ordering period from date of Contract award through twenty-four (24) months thereafter.

The Period of Performance shall be from date of Contract award through thirty-six (36) months thereafter.

2. BASIS OF COMPETITION:

a. At the Task Order level, award determination will be conducted in accordance with clause PD-I02 “ORDERING

PROCEDURES FOR DELIVERY/TASK ORDERS ISSUED UNDER MULTIPLE AWARD CONTRACTS”.

b. At the Task Order level, the Procuring Contracting Officer may conduct evaluations using the factors cited in Section H, Special Contract Requirements.

3. MULTIPLE AWARDS: As detailed in Section M, award will be made to the Offeror(s) whose offer(s) are determined to represent the best value to the Government. The Government will make award to no more than four

(4) Offerors.

a. The Multiple Award Contract resulting from this RFP will be considered complete (ineligible for issuance of additional task orders) when any of the following occur:

1. The ordering period specified in the Contract(s) has expired, OR;

2. The Government Estimate for the Program being supported by the Multiple Award Contract has been reached. The Government Estimate for the Program will be specified in the resultant award(s). OR;

3. The ceiling of any of the individual Contracts resulting from this RFP has been reached. If the ceiling of any of the Contracts is reached, the entire Multiple Award Contract is complete.

c. The minimum value of services that must be ordered from each awardee will be one (1) each of CLIN 0001. The minimum shall be satisfied by the issuance of the first Task Order issued under each resultant Contract award.

For the initial task order award(s) the offerors will be evaluated on a Low Cost Technically Acceptable (LPTA) basis to determine which offeror will receive award of any quantity above the guarenteed minimum (if applicable).

All subsequent orders will be evaluated using the criteria listed in Section H of the RFP.

4. SUBMISSION OF OFFERS:

As detailed in Section L of this solicitation, Offerors are required to submit a technical proposal as part of their offer. Offerors who are large business concerns are also required to submit a proposed SubContracting Plan in accordance with Clauses 52.219-9 entitled “Small Business SubContracting Plan” and 252.219-7003 entitled “Small, Small Disadvantaged and Women-Owned Small Business SubContracting Plan (DOD Contracts).” Offerors are advised of the requirements contained in Clauses 52.219-8, entitled “Utilization of Small Business Concerns,” 52.244-2 entitled “SubContracts - Alternate I” and 52.244-5 entitled “Competition in SubContracting” concerning proposed subContracting. Offerors are required to furnish all applicable information required by Clause 52.244-2, entitled “SubContracts - Alternate I”, as part of their offer. Failure to comply with the instructions set forth in Section L of this Solicitation or to provide all information requested may result in the determination that the proposal is nonresponsive and ineligible for Contract award(s).

5. SPECIAL NOTES:

Potential offerors should provide a response to the Contracting Specialist within 7 days of the release of this solicitation citing the place of performance if awarded a contract.

SECTION C - DESCRIPTIONS AND SPECIFICATIONS

STATEMENT OF WORK

C - STATEMENT OF WORK

NOTE TO CONTRACTOR: All offerors must have a valid General Electric (GE) Level IV licensed maintenance facility in order to be eligible for award and must provide a copy of the certificate as a part of the proposal.

C.1 Scope

This specification identifies the requirements for commercial depot level overhaul of US Navy LM2500 Paired Blade Turbine (PBT) Gas Generators, National Stock Number (NSN) 2S 2835-01-032-9125. Potential Awardees will be established commercial overhaul depots that are technically acceptable in commercial overhaul of the US Navy LM2500 PBT in accordance with the criteria outlined in this solicitation.

C.2 Applicable Documents

C.2.1 General

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 C.3 and C.4 of this specification, in addition to the specifications listed in the documents listed in Section C.2.2, Government Furnished Informtion.

C.2.2 Government Furnished Information (GFI)

US Navy LM2500 Technical Manuals:

Organizational Level:

S9234-AD-MMO-070/LM2500 latest revision S9234-AD-MMO-080/LM2500 latest revision S9234-AD-MMO-090/LM2500 latest revision Depot Level Maintenance:

S9234-AB-MMD-010/LM2500 latest revision S9234-AB-MMD-020/LM2500 latest revision S9234-AB-MMD-030/LM2500 latest revision S9234-AB-MMD-040/LM2500 latest revision S9234-AB-MMD-050/LM2500 latest revision S9234-AB-MMD-060/LM2500 latest revision

The US Navy LM2500 technical manuals will be provided after contract award to the successful offeror as Government Furnished Information (GFI). The contractor must request permission from Naval Surface Warfare Center Philadelphia Division (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.

C.2.3 Order of Precedence

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 C.2.2 of this document take precedence. These manuals are as follows:

Organizational Level Maintenance S9234-AD-MMO-070/LM2500 through S9234-AD-MMO-090/LM2500 latest revision and Depot Level Maintenance S9234-AB-MMD-010/LM2500 through S9234-AB-MMD-060/LM2500 latest revision.

C.3 Requirements

C.3.1 General

The contractor shall be a General Electric (GE) licensed Level IV maintenance and overhaul facility for the LM2500 gas generator.

The contractor shall have prior experience with the overhaul of the GE LM2500 PBT gas generator for industrial or marine customers.

The contractor shall furnish services in accordance with any written technical instructions. No verbal instructions will be accepted to the specifications set forth herein.

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 in accordance with this specification.

All overhaul work performed under this specification shall be in accordance with 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, by the cognizant technical representative at NSWCPD prior to implementation.

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 in accordance with 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 PBT 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 Statement of Work) to complete the engine overhaul, the contractor must request approval from NSWCPD Code 423 to use any alternate repair procedures.

In addition to NSN and part number (PN) markings contained herein, overhauled units shall be marked, in accordance with standard commercial practice, with the delivery order number and date of overhaul.

C.3.2 Deleted

C.3.3 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 C.4.1. 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 in accordance with 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. The contractor’s ability to demonstrate the compilation of gas generator rebuild information in a gas generator overhaul report shall be evaluated in accordance with Section L of this solicitation.

The fuel used during testing of the gas generator shall be either JP-5, Jet A1, JP-8, Jet A or marine diesel. 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 PBT 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.

C.3.4 Material

The contractor shall supply and only use US Navy approved parts in the overhaul of US Navy LM2500 PBT gas generator. All approved parts for use in US Navy LM2500 PBT 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 parts is not permitted.

C.3.4.1 Government Furnished Material (GFM), Gas Turbine Change (GTC) Upgrade Kits

The US Navy will provide the contractor with selected US Navy LM2500 Ancillary Change (AYC), Gas Turbine Bulletin (GTB) and Gas Turbine Change (GTC) upgrade kits. These kits will be provided as Government Furnished Equipment (GFE) at no expense to the contractor. The upgrade kits listed in Table 1 below, with the exception of GTC 100R3 (optional workscope meeting discussion item), are required to be installed if not already incorporated, on an as needed basis, as determined per the teardown and inspection of the engine. All US Navy LM2500 gas turbine upgrade kits to be made available as GFE are listed in Table 1. The vendor shall request the kits needed upon completion of teardown and inspection from NSWCPD Code 423, who will provide them upon request.

AYC/GTB/GTC Issue Date Subject Kits/Part Number

AYC 42 5/7/2001 PLA Connector/Cable Improvement 9042LKA129850TW

GTB 24R1AA

7/15/2002 (Latest

Amendment) Inspection/Installation of TMF Anti-Rotation Pins 135042

GTC 17 4/15/2004 CDP Rotating Air Seal 9017LKA117997TU

GTC 19 9/2/1993 Compressor Rotor Assembly 9019LKA118189TU

GTC 19 9/2/1993 Compressor Rotor Assembly Kit 2 9019LKA218190TU

GTC 28 3/28/1995 No. 5 & 6 Bearing Heat Shields & Thermal Blankets 9028LKA120165TU

GTC 29 3/28/1995 HPT Rotor Hook Bolt 9029LKA120257TU

GTC 34 3/28/1995 Cooling & Vent Seal Tube Brackets 9034LKA120432TU

GTC 45 9/1/1986 Main Fuel Pump, Plug Seating 9045LKA121637TU

GTC 51 5/1/1995 Deletion Of C- And D- Sump Lube System Check 9051LKA121788TU

GTC 52 8/1/1986 Redesign Of The PT5.4 Pressure Sensing System 9052LKA121789TU

GTC 53 12/15/1987 Replacement Of A- And B- Sumps Ejector Nozzle 9053LKA121790TU

GTC 56 8/10/1994 Compressor Rotor Stability Improvement 9056LKA123082TU

GTC 57 5/1/1995 Deletion Of Pilot Pressure Relief Valve 9057LKA123363TU

GTC 64 6/11/2004 Improved LPT Interstage Seal Bolting 9064LKA124017TU

GTC 77R3

4/30/2010 (Latest

Revision) Accelerometer Vibration Sensing System Mod on DD-963, DD-

993, CG-47 and DDG-51 Class Ships

9077LKA228126TU

GTC 79R2

1/2/96 (Issued)

3/22/01 (Latest Revision) Addition of a Vibration Dampening Bracket and Clamp on "C"

Sump Lube Supply Line

9079LKA125702TU

9079LKA225703TU

GTC 83R1 10/18/2001 Installation of New Lube and Scavenge Pump

9083LKA127123TU

9083LKA227124TU

GTC 84R2AB

7/27/92 (Issued) 3/23/94 (Latest Amendment)

Provide Improved Fuel Manifold That Incorporates Flexible Hoses

9084LKA127463TU

GTC 91 7/23/2004 Elimination Of Aerodynamic Instability 9091LKA129427TU

GTC 95 5/7/2001 Improved LM2500 PLA 9095LKA129853TU

GTC 96R1

8/1/2003 (Issued) 12/8/2004 (Latest

Revision) LM2500 Flexible T5.4 Thermocouple Harness GTC96K1R0GTM

GTC 100R3

(Optional)

1/20/2012 LM2500 Digital Fuel Control System 682L284G06

GTC 101 2/17/2004

Improved Drain System for the Fuel Shut-Off Valves

(Use AYC 39R2 Parts Kit)

9039LKA128217TW

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

The upgrade kits listed in Table 2 below are also required to be installed, unless found to be previously incorporated.

Kits listed in Table 2 must be provided by the vendor.

GTC Issue Date Subject

GTC 75 6/13/2002 Installation of Redesigned VSV Stage 5 and 6 Vane Arms

GTC 78R2 6/11/2004 Compressor Variable Stator Improvements

GTC 89 8/10/1994 Coast Metal 64 Hardcoat TMF For Wear Protection

Table 2 – Required Technical Directive Upgrade Kits (not provided as GFE, as needed)

All US Navy material shall be stored indoors, and in compliance with applicable clauses for storing Government Furnished Material. 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, in accordance with applicable clauses for material storage and control of Government Furnished Material.

C.3.5 LM2500 PBT Gas Generator Disassembly Inspection Report (CDRL A002), Work Scope Meeting and Final Invoice

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 for review. 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 vendor shall proceed with arranging the work scope meeting date. During the work scope meeting NSWCPD Code 423 will approve the amount of work that will be performed to return this 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 PBT 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 PBT gas generator accessories shall be inspected in accordance with 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 PBT gas generator shall have the overhaul work, included but not limited to, identified Sections C.3.5.1 through C.3.6 of this specification performed during the overhaul of the US Navy LM2500 PBT gas generator. All material being replaced with new, deemed to be unserviceable/unrepairable, and material removed due to kit upgrade installation shall be returned to NSWCPD Code 423 for further analysis by the Government.

C.3.5.1 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 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 in accordance with the US Navy LM2500 depot level technical manuals.

C.3.5.2 Compressor Rotor Assembly

Disassemble, inspect, clean, and process as described below and per procedures outlined in the US Navy LM2500

a. All stage 1 compressor blades shall be replaced with new material 100%.

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

c. Map all compressor rotor balance weights in accordance with 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 not to exceed 24 total weights.

d. Remove all stage 2 through 16 compressor blades for inspection, processing and recoating of dovetails.

Replace 30% of the stage 2 through 16 compressor blades with new material in each stage allowing for as required wide and narrow blade platform end gap. In each case, vendor is required to replace the worst condition components and repair/reuse the remainder.

e. Inspect for blade platform gap. If minimum gap is exceeded, install additional wide platform blades as required to reduce gap.

f. Apply new rubcoat to compressor rotor spool stages 3-9, 11-13 and 14-16. Strip old coating in accordance with (IAW) paragraphs 8.217 and 8.232 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 in accordance with the US Navy LM2500 depot level technical manuals.

C.3.5.3 Compressor Front Stator Assembly

Disassemble, inspect, clean, and process as described below and per procedures outlined in the US Navy LM2500

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. If GTC 36 not incorporated previously, comply.

c. Apply new rubcoat to compressor front stator case. Strip old Rub and Bond coating IAW paragraphs 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.

Replace 30% of the inlet guide vanes (IGV) through stage 11 compressor vanes with new material in each stage allowing for as required wide and narrow blade platform end gap. In each case, vendor is required to replace the worst condition components and repair/reuse the remainder.

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

f. Comply with GTC 75, if needed.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of

C.3.5.4 Compressor Rear Stator Assembly

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

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

b. Remove all stage 12 through 16 compressor vanes for inspection and processing. Replace 30% of the stage 12 through stage 16 compressor vanes with new material in each stage allowing for as required wide and narrow blade platform end gap. In each case, vendor is required to replace the worst condition components and repair/reuse the remainder.

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

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of

C.3.5.5 Compressor Rear Frame Assembly

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

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

b. Inspect and test CRF oil tubes for cracks.

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

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

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

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

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

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

i. Pressure test sumps.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of

C.3.5.6 Combustor Assembly

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

a. Disassemble, inspect, clean, and process.

b. 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: If incoming gas generator already has an HS 188 dome installed, replacement is not necessary.

Remove existing HS 188 dome, inspect, clean, process and reinstall.

c. All serviceable fuel nozzles require complete overhaul in accordance with US Navy LM2500 depot level technical manual. Flow and test only is not acceptable.

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

C.3.5.7 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.

a. Rework all high pressure turbine (HPT) stage 1 nozzles.

b. Replace all HPT stage 1 shrouds with new material 100%.

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

C.3.5.8 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

a. Rework all HPT stage 2 nozzles.

b. Replace all HPT stage 2 shrouds with new material 100%.

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

Reworked HPT stage 1 and 2 blades should be PtAl coated. Newly provided OEM HPT stage 1 and 2 blades, if necessary, should be BC22 coated.

C.3.5.9 High Pressure Turbine Rotor Assembly

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

a. Rework all HPT stage 1 and stage 2 blades.

b. Complete HPT stage 1 and stage 2 blade repairs required; mini tip repairs are not acceptable.

c. Comply with GTC 29, as applicable.

d. 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.

d. Remove aft shaft, pressure tube and inspect.

e. Remove borescope plugs, inspect in accordance with 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 in accordance with the US Navy LM2500 depot level technical manuals.

C.3.5.10 Turbine Mid Frame Assembly

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

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

b. Replace No. 5 and 6 bearing heat shields per GTC 28, as applicable.

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

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

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

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

g. Pressure test sumps.

h. Incorporate Gas Turbine Bulletin (GTB) 24R1, as applicable.

Note: Any conditions found that exceed the technical manual service limits require repair or replacement of

C.3.5.11 Inlet Gearbox Assembly

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

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

b. 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 in accordance with the US Navy LM2500 depot level technical manuals.

C.3.5.12 Transfer/Accessory Gearbox Assembly

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

a. Disassemble to allow for accessory gearbox bearing processing.

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

c. 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

C.3.5.13 Accessories

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

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

b. Remove and inspect starter for foreign object damage. Comply with gas turbine changes to meet requirements of Section C.3.6.

c. 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 C.3.6.

d. Remove fuel pump, inspect and clean strainer element, modify for eductor plug seating per GTC 45, as applicable. Test per paragraph 26-16 of US Navy LM2500 depot level technical manual. Comply with gas turbine changes to meet requirements of Section C.3.6.

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

f. Remove and bench test fuel shut-off valves per paragraph 29.13 of US Navy LM2500 depot level technical manual. Comply with Gas Turbine Change (GTC) 101, as applicable.

g. 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 C.3.6.

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

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

j. Inspect and repair as required and test power level angle (PLA) actuator. Comply with GTC 95, as applicable.

k. 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.

l. Inspect PT 5.4 probes, pigtails, and manifold per paragraph 47.7 of US Navy LM2500 depot level technical

m. Inspect fuel manifold for end connector cracks. Comply with GTC 84R2, as applicable.

n. Inspect and test overspeed transducer leads per paragraph 47.18 of US Navy LM2500 depot level technical

o. 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. Comply with GTC 83R1, as applicable.

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

q. 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.

r. VSV actuator – perform bench test. Repair/replace if limits are not met per paragraph 32.13 of US Navy LM2500 depot level technical manual. Comply with GTC 78R2, as applicable.

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

t. 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.

u. Inspect and test ignition exciter per Chapter 39 of US Navy LM2500 depot level technical manual. If inducted US Navy LM2500 PBT 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.

v. If inducted US Navy LM2500 PBT 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.

w. If inducted US Navy LM2500 PBT 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.

x. If inducted US Navy LM2500 PBT 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

C.3.6 LM2500 PBT Gas Generator Accessory Upgrade Configuration After Overhaul

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

a. Main Fuel Control (MFC) L16716P25

b. Fuel Pump 9039M45P09 (9255-06A6) or 9039M45P04

c. Lube and Scavenge Pump L24407P07

d. PLA Actuator L22263P09

e. CIT Sensor L21225P02

f. Starter L34085P08

All US Navy LM2500 PBT gas generator DFC accessories (if CLIN 0030 is required) shall be of the following configuration after overhaul:

a. Hydraulic Pump/VSV Servo 9902-439 (L44569P29)

b. Fuel Pump 9039M45P09 (9255-06A6) or 9039M45P04 (9255-04A6)

c. Lube and Scavenge Pump L24407P07

d. VSV Actuator 9902-407 (L34358P10)

e. CIT/CIP Sensor L34319P01

f. Starter L34085P08

All US Navy LM2500 PBT gas generators shall have the mandatory Gas Turbine Technical Directives (TDs), AYCs/GTBs/GTCs, listed in Tables 1 with the exception of GTC 100R3 (optional workscope meeting discussion item) and 2 incorporated during the overhaul, if not previously incorporated. NSWCPD Code 423 will provide the upgrade kits to the contractor to incorporate kits per Table 1at no cost to the contractor. For the kits listed in Table 2

(GTCs 75, 78 and 89) the contractor will have to provide associated material if these kits are not already incorporated.

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.