One Time Gas Turbine Component Repair.pdf

USCG - SFLC

R-234-0185 Dated 03/2022

REVISION __

REVISION No: __ CHANGE No:

OVERHAUL SPECIFICATION

FOR ONE TIME

PRATT & WHITNEY MODEL FT4A

GAS TURBINE COMPONENTS

USED ON 399 FT CUTTERS

ORGINATED BY: D. T. Jacobs DATE: 03/2022

ORIGINATOR’S COMMAND: Surface Forces Logistics Center (SFLC)

DEPARTMENT / DIVISION: Long Range Enforcer Product Line

INTERNAL REVIEWER: DATE:

Dated 03/2022

REVISION __

OVERHAUL SPECIFICATION FOR PRATT AND WHITNEY FT4A GAS

TURBINE COMPONENTS 1.0.SCOPE

1.1.This document sets forth the requirements for the receipt, disassembly, inspection, condition/test report, overhaul/repair, re-assembly, testing, preservation, packing, packaging and marking of Coast Guard configured gas turbine components.

1.2.GOVERNMENT FURNISHED PROPERTY (GFP) Pratt &Whitney Gas Turbine Components

1.2.1. Group I Components – Fuel Manifolds

a. Fuel manifold set 18:1 nozzle/RH PN:1046717 NSN:3835-01-083-4283

1.2.2. Group II Components – Combustion Chambers

a. Combustion chambers position 1,3,7 PN:699766 NSN:2835-01-374-3398

b. Combustion chambers position 2,6,8 PN:699767 NSN:2835-01-374-1944

1.3.GOVERNMENT FURNISHED MATERIAL (GFM): The government reserves the right to provide, at its option, the following: assemblies, sub-assemblies, equipment or parts as GFM for use at any time during the contract period.

2.0.APPLICABLE DOCUMENTS:

2.1.GENERAL – The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of the documents cited in section 3, 4, or 5 of this specification, whether or not they are listed here.

2.2.GOVERNMENT DOCUMENTS - The following specifications and standards form a part of this specification to the extent specified herein. Unless otherwise specified, the documents listed here by number and date shall be those in the current Department of Defense Index of Single Stock Point of Specifications and Standards (DODSSP) and supplements thereto.

2.2.1. United States Coast Guard USCG-SFLC Specification D-000-0100 Rev G Dated 06/2006, Bar Coding for USCG Surface Forces Logistics Center Material.

Dated 03/2022

REVISION __

2.3.COMMERCIAL DOCUMENTS - The following documents form a part of this specification to the extent specified herein. The documents shall be the version listed by number and date from the referenced industry organization. It is the responsibility of the vendor to obtain all the applicable/required documents from the OEM.

2.3.1. Pratt & Whitney/Turbo Power and Marine Systems Inc.:

a. GG4 Industrial Overhaul Manual, P/N 544026, up through revision 15, dated

10/15/91 as applicable for FT4A Marine Gas Turbines.

b. Marine Engine Overhaul Standard Practices Manual, P/N 52A138, (most current revision)

c. Pratt & Whitney Power Systems Marine Gas Turbine Engine Illustrated Parts

Catalog, P/N 547055A, dated 01 July 1993, revised 30 August 2010

d. FT4 Industrial Power Turbine Overhaul Manual, P/N 599129, as applicable for FT4A Marine Power Turbines dated 15 March 1977

2.3.2. American National Standards Institute (ANSI), National Conference of

Standards Laboratories (NCSL), American Society for Quality (ASQ) and American Society for Testing and Materials (ASTM)

a. ISO/IEC 17025:2017 Requirements for the Calibration of Measuring and Test

Equipment

b. ANSI/ASQ/ISO 9001, Dated 2015, Quality Management Systems

c. ASTM D3951-18, Dated 11/12/2022, Standard Practice for Commercial Packaging

2.3.3. Document Availability – For the methods and conditions for obtaining copies of these reference documents, see section 6.0

2.4.SPECIFICATION ORDER OF PRECEDENCE - In the event of a conflict between the text of this specification and the references cited herein, this specification shall take precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0.REQUIREMENTS:

3.1.GENERAL - Inspections, repair/overhaul and testing for the Gas Turbine components shall be accomplished in accordance with Wood Group Pratt & Whitney, the Original Equipment Manufacturer (OEM) procedures as detailed in the GG4 Industrial Overhaul

Dated 03/2022

REVISION __

Manual P/N 544026 and all OEM overhaul standard practices and applicable documents listed in section 2.0 of this specification.

3.1.1. Service and Spare Parts Bulletins listed in section 3.5.1 not previously accomplished shall be listed in the condition reports. Upon the Contracting Officer’s approval, the service and spare parts bulletins shall be completed during repair/overhaul.

3.1.2. Upon completion of repairs and any required testing, the Gas Turbine components shall be in ready to operate configuration, preserved and packaged in their respective containers, in accordance with section 5.0 of this specification.

3.1.3. Authority to Proceed: The Contractor shall not begin any repair or component replacement until authorized in writing by the Contracting Officer. This authorization will provide specific guidance on what type and level of work to be accomplished, or approve disposal of any Gas Turbine component deemed non-repairable, as determined by the Contracting Officer.

3.1.4. The Contractor shall provide inside storage for the Gas Turbine components immediately following receipt of the parts/assemblies.

3.1.5. The Contractor shall provide a separate line item cost for the repair or replacement of the shipping container.

3.1.6. Prior to Coast Guard acceptance of the completed component(s), a Corporate

Officer of the Contractor, authorized to legally bind the corporation, shall certify in writing that they have repaired/overhauled, re-assembled and tested (if required) the Gas Turbine component(s) in accordance with Wood Group Pratt & Whitney specifications, standards and recommended procedures. Two copies of the Certificate of Conformance shall be provided: One copy packed with the component(s) and one copy forwarded to the Contracting Officer.

3.1.7. The Contractor shall be responsible for notifying the Contracting Officer a minimum of ten (10) calendar days prior to the Contractor being ready for any inspections and or tests.

3.2.REPORTS - The Contractor shall submit the following reports, in writing, to the

Contracting Officer for each delivery order issued.

3.2.1. Initial Receiving Report: Required thirty (30) calendar days after the receipt of GFP specified on this contract. This report shall outline the general condition of the property or material and include:

Dated 03/2022

REVISION __

a. A validation of part number, serial numbers, any damage noted, and a listing of any material found missing.

b. Information regarding the condition of shipping container(s) with recommended repairs.

3.2.2. Disassembly Condition Inspection Report: Required thirty (30) calendar days after submittal of the Initial Receiving Report. The report shall be organized and identified by each component(s) part number, serial number, delivery order number, and contract number. The report shall also include the following information:

a. Component configuration

b. Service and Spare Parts Bulletins Required

c. Inspection results

d. Repairs required

e. Parts required

f. A complete cost breakdown for all parts and labor

g. Repairs to the shipping container

h. List of parts to be scraped

i. The Coast Guard will review the report upon receipt and the Contracting

Officer will provide the Contractor with specific direction on what type and level of work to accomplish.

3.2.3. Reassembly Report: Required fourteen (14) calendar days after completion of repair/overhaul of the component(s) and any testing required. The report shall include all required inspections, fits, and clearances as per the overhaul manual for final assembly.

3.2.4. GFP and GFM Report: Required whenever GFP/GFM is considered unusable or unacceptable for any reason, within fifteen (15) calendar days after receipt of the discrepant GFP/GFM. This report shall provide a detailed explanation as to why the GFP/GFM must be rejected along with recommendations for USCG retention or disposal.

3.3.INITIAL RECEIPT OF UNIT: The Contractor shall notify the Contracting Officer within thirty (30) calendar days of the receipt of GFP specified on this. This report shall include a validation of part number, serial numbers, any damage noted, and a listing of any material found missing and information regarding the condition of shipping container(s) with recommended repairs. Missing item(s) (including tubing, clamps, brackets, covers, etc.) shall be included in the condition inspection report. The Coast Guard reserves the right to have a representative present when any GFP/GFM container is opened. The Contractor shall also complete the requirements of section 3.2.1.

Dated 03/2022

REVISION __

3.4.DISASSEMBLY CONDITION INSPECTION: The Contractor shall disassemble the Gas Turbine component(s) and inspect all components as per the OEM manual (including all Non Destructive Tests (NDT)) to develop a Disassembly Condition Inspection Report as per section 3.2.2.

3.5.REPAIRS: All repairs shall be performed in accordance with the overhaul manual and all other applicable documents referenced in section 2.0. The following repair requirements shall not limit the Contractor’s repair scope of authorized OEM repairs, service and spare parts bulletins for the component(s). All repairs required/recommended shall be noted in the Disassembly Condition Inspection Report and include service and spare parts bulletins not previously accomplished. No repair shall be accomplished without authorization from the Contracting Officer, see section 3.1.3.

3.5.1. Group I components – Fuel Manifolds

a. Section 1.2.1.a.: The Contractor shall provide all equipment, labor, parts and material required to repair/overhaul and test the fuel manifolds. Service bulletin 74B21 applies.

3.5.2. Group II components – Combustion Chambers

a. Section 1.2.2.a. and 1.2.2.b.: The Contractor shall provide all equipment, labor, parts and material required to repair/overhaul the combustion chambers (6997XX series) in accordance with the overhaul manual and all applicable documents in section 2.0.

3.6.PARTS: The Contractor shall use only parts approved by Wood Group Pratt & Whitney, the OEM. This is in accordance with Wood Group Pratt & Whitney policy, which includes the GG4 Industrial Overhaul Manual, Marine Engine Overhaul Standard Practices Manual and Pratt & Whitney and Joint Venture Service Bulletins specifically. All new or refurbished parts shall be Wood Group Pratt & Whitney approved for marine application.

The Contractor shall provide documentation on the acquisition of parts used on the gas turbine component(s) with final invoicing.

3.6.1. Scrap and Discarded Parts: Parts and/or assemblies deemed scrap by the

Contractor shall be secured in a designated storage area, individually tagged as scrap and include the serial number, part number and the reason for rejection.

Expendable/consumable parts shall be kept together in a designated container.

a. Scrap Parts/assemblies shall be returned to the Coast Guard by the Contractor or disposed of at the Contractor’s facility as directed by the Contracting Officer.

Dated 03/2022

REVISION __

3.7. REASSEMBLY: Gas Turbine component(s) shall be reassembled in accordance with cited documents in section 2.3.1 of this specification.

3.8.OVERHAUL: Gas Turbine component(s) shall be overhauled and tested within 40 calendar days of receipt of Coast Guard authority to proceed in accordance with cited documents in section 2.3.1 of this specification.

3.9.TESTING: The Gas Turbine component(s), if required by the overhaul manual, shall be tested in a ready to operate condition to the Coast Guard configuration.

3.10. WARRANTY: The Contractor shall provide a warranty as per section “H” of this solicitation/contract for each component repaired/overhauled.

4.0.QUALITY ASSURANCE:

4.1.RESPONSIBILITY FOR INSPECTION: The Contractor is responsible for the performance of all inspection requirements as specified herein. The Contractor may use his own or any other facilities for the performance of the inspection and tests, unless disapproved by the Coast Guard. The Coast Guard reserves the right to perform or witness any of the inspections and tests set forth in this specification at any time.

4.2.RESPONSIBILITY FOR COMPLIANCE: All items shall meet the requirements of this specification. The inspections set forth herein shall become part of the Contractor’s overall inspection system or quality program. The absence of any inspection requirement in this specification shall not relieve the Contractor of the responsibility of assuring that all products or supplies submitted to the government for acceptance comply with all requirements of the contract. Sampling for quality conformance does not authorize submission of known defective material (either indicated or actual) nor does it commit the government to acceptance of defective material.

4.3.QUALITY CONTROL PROGRAM: The Contractor shall maintain a Quality Control

(QC) Program conforming to ANSI/ASQ/ISO Q9001-2015. The program shall be documented and submitted to the Contracting Officer for approval, prior to the start of the contract.

4.4.CALIBRATION SYSTEM: The Contractor shall maintain a test equipment calibration program conforming to ISO/IEC 17025:2017. The Contractor shall have a copy of the calibration program on hand during the term of this contract for review by any Coast Guard representative when requested.

5.0.PRESERVATION, PACKING, PACKAGING AND MARKING:

5.1.PRESERVATION: Gas Turbine components shall be in a ready to operate configuration stored in their respective containers. Gas Turbine components shall be prepared for long

Dated 03/2022

REVISION __

term storage in accordance with the GG4 Industrial Gas Turbine Overhaul Manual PN:

544026 and all other applicable documents referenced in this specification. All fluids shall be drained from each component(s); all flanges, fittings, openings and nozzles shall be capped with plastic protective caps.

5.2.PACKING AND PACKAGING: Components shall be packaged in accordance with section 2.3.2.c using commercial grade packaging. Each component shall be packed individually in its own “Commercial” grade box, which shall be capable of providing adequate protection to the item during multiple shipments. The packing list shall state the Contract Number, Delivery Order Number and all item (s) contained in the container.

One copy shall be placed inside the box and another copy shall be attached to the exterior of the box.

5.3.WARNING TAG: A red tag, marked “Preservation Actions/De-preservation Actions

Required” shall be attached to each unit when such actions have been taken. A typewritten notice of all preservation actions taken, safety precautions, and related Material Safety Data Sheets shall be attached with the warning tag.

5.3.1. Additionally, specific instructions to restore the unit to operating condition, including minor items such as removing plastic plugs, caps, fittings, etc., shall be provided. The instructions on this notice shall be detailed and complete so that no other reference is needed to de-preserve the unit.

5.4.MARKING FOR SHIPPING CONTAINER:

5.4.1. Each shipping container shall be marked on two opposite sides. The markings shall be made with machine-made stencils; the lettering / numbering shall be a minimum of ½ inch high, in permanent black printed characters on a highly contrasting “white painted” background.

a. All previous markings and labels shall be completely removed from the reusable shipping container prior to the applications of any new markings.

Stock Number: “As submitted” Component Name: “As submitted” Serial Number: “As per enclosed item” Quantity & unit issue: 1 EA Gross Weight: “As determined” Date Shipped: “From the Contractor” Contract Number:“See contract page 1” Coast Guard SFLC Material” Condition “A”

5.5. BAR CODING: Bar code labels shall be on all items shipped to the Coast Guard. All bar coded labels shall be in accordance with SFLC specification D-000-0100 Rev G

Dated 03/2022

REVISION __

Dated 06/2006. The actual label shall be Type “V” Grade “B” Style “2” Composition “a”. Each label shall contain encoded data for the Stock Number.

6.0.NOTES:

6.1.GOVERNMENT & COMMERCIAL DOCUMENT SOURCE

6.1.1. GOVERNMENT DOCUMENTS

Department of Defense Single Stock Point (DODSSP Documents) 700 Robbins Avenue Building #4, Section D Philadelphia, PA 19111-5098

FAX (215) 697-9398

http://dodssp.daps.dla.mil/

DOD & Navy Publications & Forms (Other than DODSSP) Naval Publication and Forms Center 5801 Tabor Ave.

Philadelphia, PA 19120

(215) 697-2197

U.S.C.G. Surface Forces Logistics Center Long Range Enforcer Product Line Mail Stop 26, Bldg. 3, 2nd Floor 2401 Hawkins Point Road Baltimore, MD. 21226-5000 Attn: Patricia Dobbins

6.1.2. COMMERCIAL DOCUMENTS

Wood Group Pratt & Whitney Industrial Turbine Services, LLC 1460 Blue Hills Avenue Bloomfield, CT 06002

(860) 856-4600

American National Standards Institute (ANSI) 25 West 43rd Street (Between 5th and 6th Avenues) 4th Floor New York, NY 10036

212-642-4900 FAX

212-398-0023 www.ansi.org

Dated 03/2022

REVISION __

ASTM international American Society for Testing Materials (ASTM) 100 Barr Harbor Drive P.O. Box C700 West Conshohocken, PA 19428-2959 610-832-9585 www.astm.org