N6449820R0001_0001.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 correct adminstrative errors. See Continuation Page.

1. CONTRACT ID CODE PAGE OF PAGES

1 17

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

16C. DATE SIGNED

BY 11-Feb-2020

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 N6449820R0001

X 9B. DATED (SEE ITEM 11)

06-Feb-2020

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 is extended, X 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 1 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

11-Feb-2020

CODE

NAVAL SURFACE WARFARE CENTER PHILA

CODE 02311, KAREN JOHNSON

215-897-7062, KAREN.JOHNSON2@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:

N6449820R0001

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 1

The Point of Contact (POC) for this amendment is Karen Johnson, Karen.Johnson2@navy.mil The purpose of the amendment is as follows:

1. CLIN 0004 description has changed to CDRL A008

2. Section 3.6 of the SOW (paragraph 2) US Navy LM2500 “PBT” has changed to “SST”

3. Section 3.10.1.A.I of the SOW “Controllable-Pitch-Propeller Blade Set and Fixed-Pitch

Monobloc Propeller (two timelines total)” has changed to “LM2500 SST gas generator” All other terms and conditions of this solicitation remains unchanged.

SECTION B - SUPPLIES OR SERVICES AND PRICES

CLIN 0004

The CLIN description has changed from Priced CDRL A007 to Priced CDRL A008.

The CLIN extended description has changed from:

Technical Data in accordance with DD Form 1423. Priced CDRL A009 in the amount of $500. See Section C.

To:

Technical Data in accordance with DD Form 1423. Priced CDRL A008 in the amount of $500. See Section C.

SECTION C - DESCRIPTIONS AND SPECIFICATIONS

The following have been modified:

STATEMENT OF WORK

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 the In-Service Engineering Agent (ISEA) responsible for electrical power and generation systems installed on surface ships, submarines and 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

a). The services to be delivered under this Contract/Task Order 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.

b). 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.

c). 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.

d). Employee Relationship:

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.

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.

e). Inapplicability of Employee Benefits: This Contract does not create an employer-employee relationship. Accordingly, entitlements and benefits applicable to such relationships do not apply.

f). Notice. 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) 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.

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:

(i) Confirm the conduct is in violation and when necessary direct the mode of further performance,

(ii) Countermand any communication regarded as a violation,

(iii) Deny that the conduct constitutes a violation and when necessary direct the mode of further performance, or

(iv) In the event the notice is inadequate to make a decision, advise the Contractor what additional information is required, and establish the date by which it should be furnished by the Contractor.

1.1 BACKGROUND

NSWCPD has the requirement for commercial depot level overhaul of US Navy, US Coast Guard, Military Sealift Command and Foreign Military Navy LM2500 Single Shank Turbine (SST) Gas Generators, National Stock Number (NSN) 2S 2835-01-237-1153. The LM2500 SST Gas Generator was designed and manufactured by General Electric (GE) and is utilized by the U.S. Navy as the main propulsion Gas Turbine engine aboard over 100 surface combatants including FFG 7, CG 47, and DDG 51 ship classes.

1.2 SCOPE OF WORK

This specification identifies the requirements for commercial depot level overhaul of US Navy, US Coast Guard, Military Sealift Command and Foreign Military Navy LM2500 Single Shank Turbine (SST) Gas Generators, National Stock Number (NSN) 2S 2835-01-237-1153.

2.0 APPLICABLE DOCUMENTS

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 Information.

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 Contractor(s) 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. 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 of GE, including but without limitation, it is not to be used in creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or configuration changes or to obtain FAA or any other Government or regulatory approval to do so.

When available, copies of the Marine Gas Turbine logbook and any borescope inspection results will be provided at the Task Order level to the Contractor for each US Navy LM2500 SST gas generator undergoing commercial overhaul as Attachment 002.

A list of consumable material for each US Navy LM2500 SST gas generator is provided as Attachment 1.

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.

3.0. REQUIREMENTS

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 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, 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 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 Statement of Work) to complete the engine overhaul, the Contractor must request approval from NSWCPD Code 423, and the Contracting Officer to use any alternate repair procedures, IAW Contract Data Requirement List (CDRL) A004 – Request for 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 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 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 and the Contracting Officer’s Representative (COR), 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. 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.

3.3 Material

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.

3.3.1 Government Furnished Material (GFM), Gas Turbine Bulletin (GTB), Gas Turbine Change (GTC) Upgrade Kits

The US Navy will provide the Contractor with selected US Navy LM2500 Gas Turbine Bulletin (GTB) and Gas Turbine Change (GTC) upgrade kits. These kits will be provided as Government Furnished Material (GFM) at no expense to the Contractor. The upgrade kits listed in Table 1 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. All US Navy LM2500 gas turbine upgrade kits to be made available as GFM are listed in Table 1. 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 engine is inducted, Code 423 can provide the contractor with what TDs are installed based on MGTIS, but it is required that the contractor inspect and verify so they know for certainty which TD kits they need to request from the Navy. If TD kit(s) are already installed on the engine, the Contractor is required to repair the kit(s), as necessary.

GTB/GTC Issue Date Subject Kits/Part Number

GTB 24R1AA

7/15/2002 (Latest

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

GTC 96R1

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

Revision) LM2500 Flexible T5.4 Thermocouple Harness GTC96K1R0GTM

GTC 100R4

(Optional)

1/19/2018 (Latest Revision)

LM2500 Digital Fuel Control System 682L284G06

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 SST Gas Generator Disassembly Inspection Report, Work Scope Meeting and Final Invoice

Prior to the work scope meeting the Contractor shall provide the final Disassembly Inspection Report (DIR) “CDRL A002 – Disassembly and Inspection Report” and proposed work scope changes to NSWCDPD Code 423, Contracting Officer, and COR 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 Contractor shall proceed with arranging the work scope meeting date. During the work scope meeting NSWCPD Procuring Contracting Officer (PCO) will approve the amount of work that will be performed 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 Sections C.3.5.1 through C.3.6 of this specification performed during the overhaul of the US Navy LM2500 SST 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 at the contractor’s expense following complete overhaul and acceptance of the US Navy LM2500 SST gas generator.

3.4.1 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.

3.4.2 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%. 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.

d. 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.

e. 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.

f. 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

3.4.3 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.

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

3.4.4 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 Paragraph 8.159 of US Navy LM2500 depot level technical manual.

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

c. 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.

3.4.5 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 bearings 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

3.4.6 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: 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.

c. 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

3.4.7 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

a. 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.

b. 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. The Contractor is responsible for paying for shipping, removal of shrouds back to the US Navy following the overhaul and acceptance of the US Navy LM2500 SST gas generator. The Contractor is also responsible for providing the new shrouds as stated already.

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.

3.4.8 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

a. 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.

b. 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.

3.4.9 High Pressure Turbine Rotor Assembly

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

a. 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. The Contractor is responsible for paying for shipping, removal of shrouds back to the US Navy following the overhaul and acceptance of the US Navy LM2500 SST gas generator. Replacement blades will be provided by NSWCPD.

b. 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.

c. Remove aft shaft, pressure tube and inspect.

d. 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.

3.4.10 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.

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 bearing per Paragraph 8.42 of US Navy LM2500 depot level technical manual.

e. Replace No. 6 main bearing with new bearing 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 GTB 24R1, as applicable.

i. 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.

3.4.11 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 IAW the US Navy LM2500 depot level technical manuals.

3.4.12 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 (AGB) bearing processing. Replace any AGB bearing which exceeds manual inspection criteria with new bearing.

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

3.4.13 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.3.5.

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.3.5.

d. 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 C.3.5.

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.

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.3.5.

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.

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 manual.

m. Inspect fuel manifold for end connector cracks.

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

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.

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.

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 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.

v. 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.

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

x. If inducted US Navy LM2500 SST gas generator is configured with DFC, remove hydraulic pump/VSV servo (PN L44569Pxx) and turn into OEM, 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

3.5 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:

Part Numbers

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 SST gas generator DFC accessories shall be of the following configuration after overhaul:

Part Numbers

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 SST gas generators shall have the mandatory Gas Turbine Technical Directives (TDs), GTBs/GTCs, listed in Table 1 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 1 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.

3.6 Technical Approval (CDRL A004)

Deviations from the latest revisions of US Navy LM2500 depot level technical manuals, listed in Section C.2.2 of this document, such as waivers, engineering change proposals, material substitutions, engineering directives or alternate overhaul methods, not specifically stated in these manuals shall only be permitted after processing deviations and obtaining written approval from NSWCPD Code 423 and the Contracting Officer IAW CDRL A004.

All processes, procedures, inspection criteria, and components used in the overhaul of US Navy LM2500 SST gas generator shall be approved by NSWCPD Code 423 and the Contracting Officer for use or implementation in the gas generator overhaul. Approved procedures and components are listed in the US Navy LM2500 technical manuals, outlined in Section C.2.2 of this document. The US Navy upon written request will evaluate additional procedures and components not listed in the aforementioned technical manuals on a case-by-case basis.

Commercially equivalent procedures will be considered but are not approved for use without written authorization from NSWCPD Code 423 and the Contracting Officer.

3.7 Receipt Reporting (CDRL A001), Shipping Container Test (CDRL A001), Inspect (CDRL A001), DIR (CDRL A002) and Analyze the LM2500 SST Gas Generator NSN 2S 2835-01-237-1153

The Contractor shall store the LM2500 SST gas generator inside its nitrogen pressurized shipping container from the time of receipt of the asset up until the induction of the gas generator for overhaul. After the gas generator overhaul and operational testing is completed, the gas generator shall be stored in the shipping container. At all times, before and after overhaul, when the gas generator is stored in the shipping container, the container shall be pressurized with nitrogen to preserve the components. Detailed instructions for the care of the US Navy gas turbine shipping container is outlined in the US Navy technical manuals S9234-AA-MMA-000/LM2500 Section 2-169 latest revision, and S9234-AB-MMD-030/LM2500 Chapter 14 latest revision.

Within five (5) working days after receipt of the US Navy LM2500 SST gas generator, the Contractor shall contact NSWCPD Code 423 and the COR, to confirm the serial number of the gas generator received, and physical condition of the shipping container IAW CDRL A001.

If the shipping container is unable to hold the nitrogen charge when the container is received, or at any other time when the gas generator is stored in the shipping container, the Contractor shall notify NSWCPD Code 423 and the COR within two (2) working days IAW CDRL A001.

Within five (5) working days of container opening and receipt inspection of the US Navy LM2500 SST gas generator, the Contractor shall contact NSWCPD Code 423 and the COR to report all parts/components that are missing, damaged or cannibalized IAW CDRL A001. Contractor formatted report is acceptable.

The Contractor shall disassemble, as necessary, to incorporate mandatory TDs, as noted previously in Table 1, comply with LM2500 SST gas generator work scope requirements as defined in Sections C.3.4 through C.3.5 and maintain integrity of standard configuration.

Within forty-five (45) working days of container opening, the Contractor shall provide an initial DIR to NSWCPD Code 423 and the COR IAW CDRL A002. Within seventy-five (75) working days of container opening, the Contractor shall provide a complete and final DIR to NSWCPD Code 423 and the COR IAW CDRL A002 that includes all final parts/components inspection results including final findings from outsourced Contractors. Partial reports are not permitted beyond the seventy-five (75) working days of container opening. Inspection is necessary to determine the extent of failures requiring repairs, conduct metallurgical evaluations. The analysis shall result in a DIR on all SST gas generator’s and concurrent parts, assemblies, or selected component items that are inducted for processing.

All inspection criterion, procedures, and modifications shall be IAW Sections C.3.3.1, C.3.4 through C.3.5, supplemented utilizing the US Navy LM2500 depot level technical manuals outlined in Section C.2.2. Replacement parts shall be provided and comply with the LM2500 Technical Manual noted in Illustrated Parts Breakdown S9234-AD-MMO-070 through S9234-AD-MMO-090/LM2500. Only parts listed in the Illustrated Parts Breakdown for the assigned technical manuals shall be used in the overhaul of US Navy LM2500 SST gas generator.

Navy LM2500 SST gas generator.

3.8 Engineering Change Proposals

A list of currently approved US Navy LM2500 ECPs can be found in Table 2, below:

ECP

Number

Title

N-324 LM2500 Commonality Changes:10.1 # 7R/7B Lube Nozzle, 10.2 #4R Heat Shield & B Sump Insulation Blankets

Table 2: Approved LM2500 ECPs

3.9 Gas Generator DIR (CDRL A002) and Overhaul Report (CDRL A003)

Disassembly Inspection Reports (DIR): The DIR captures the serviceability of all gas generator components during teardown. Engineering analysis is performed of the removed parts, assemblies, or components in order to determine the cause(s) or the symptoms which precipitate removal and of other conditions not meeting acceptance criteria.

The analysis shall result in a DIR on the SST gas generator and concurrent parts, assemblies, or selected component items that are identified for induction and processing. The format of a DIR report is provided IAW CDRL A002.

Within sixty (60) working days after completion of overhaul, the Contractor shall compile a gas generator overhaul repair report in the Contractor’s format. This report shall be submitted to NSWCPD Code 423 and the COR IAW CDRL A003. The Contractor shall submit a DIR and overhaul repair report related to the LM2500 SST gas generator condition recorded during induction, recommendations, all parts replaced, and actions taken during repair.

3.10 REPAIR TURN AROUND TIME (RTAT) REPORT (CDRL A008)

3.10.1 The Contractor shall provide a report detailing the following information, as a minimum, to be provided in a Microsoft Project or similar format:

A. Repair Turn-Around-Time (RTAT) I. The contractor shall provide a detailed step-by-step timeline inclusive of critical milestones for a typical LM2500 SST gas generator.

II. The timeline shall be broken out by each step in the pre-repair and repair process and have a turn time associated with each step in the process.

III. For each step in the repair process, also detail what resources are required to complete each step (material, personnel, machinery, GFM, etc.). For material, typical quantities must be noted. For personnel, labor categories and expected hours for each must be noted.

IV. Each turn-time listed must reflect two scenarios: 1) what the turn time would be if the vendor had no other work in their shop (OPTIMISTIC); and, 2) what the turn time would be accounting for the typical outside workload the vendor experiences (REALISTIC).

V. The contractor shall point out what steps in the pre-repair and/or repair process are considered bottlenecks in the repair process, including their assessment of the cause for such bottlenecks typically experienced.

B. Work-In-Progress (WIP)

I. The contractor shall provide a detailed statement on what their facility’s typical work-in-progress has been over the previous three years.

4.0 Testing Requirements

4.1 General

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.

The Contractor shall notify NSWCPD Code 423 and the COR fourteen (14) calendar days prior to any gas generator testing, in order for a Government representative to be present during the testing IAW CDRL A005.

Within five (5) working days after completion of performance test of the US Navy LM2500 SST GG, the Contractor shall provide performance data corrected to the standard US Navy day, ambient temperature of 100 degrees Fahrenheit and ambient pressure of 14.7 psia IAW CDRL A005.

Data from any and all testing will be enclosed in the gas generator overhaul repair report produced by the Contractor

IAW CDRL A003.

5.0 Quality Assurance

5.1 General

FAR Clause 52.212-4, Contract Terms and Conditions - Commercial Items, is incorporated into this solicitation and any resultant Contract(s); therefore, Contractor (s) shall provide the standard commercial warranty for services provided under this scope of work IAW 52.212-4.

The Contractor shall maintain an internal component tracking system within their facility.

The Contractor shall allow for the gas generator to have a borescope inspection performed by US Navy personnel at the Contractor’s facility after the acceptance test is completed and passed. The gas generator shall meet or exceed all US Navy standards before acceptance, see Chapter 13 for details. Any components that are deemed unsatisfactory by the US Navy inspectors shall be replaced before the US Navy accepts the gas generator. The rejection of components and/or the classification of unsatisfactory will be IAW the criteria specified in the US Navy technical manuals listed in Section C.2.2 of this document. Components that are deemed unsatisfactory shall be replaced at no additional cost to the US Navy.

Subsequent to the acceptance test and borescope inspection, the gas generator 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.

6.0 Visitations by the Government

Visits by US Navy personnel will be coordinated with the Contractor based on appropriate production milestones where such a visit is deemed appropriate by the Government. The Government reserves the right to conduct a facility audit at any time during the Contract period of performance.

7.0 SECURITY REQUIREMENTS

N/A

8.0 PLACE OF PERFORMANCE

8.1 Performance will occur at the contractor(s) facility.

9.0 COUNTERFEIT MATERIAL PREVENTION (CDRL A007)

9.1 Non-Electronic Material

Department of the Navy contractors (and their subcontractors at all tiers) who obtain critical or high-risk material shall implement a risk mitigation process as follows:

If the material is currently in production or currently available, solicitations shall require the material to be obtained only from…