Solar Turbine Overhaul

THIS IS A SOURCES SOUGHT NOTICE ONLY, 2219-SS41 and a SOLICITATION IS NOT CURRENTLY AVAILABLE The United States Department of Agriculture, APHIS is issuing this sources sought synopsis as a means of conducting market research to identify parties having an interest in and the resources to support this requirement for: Statement of Work (SOW) Project: Combustion Turbine #2 Engine Rebuild and Generator Reconditioning GENERAL INFORMATION 1.0 Scope of Work Solar Turbine Engine Rebuild and Generator Reconditioning. 2.0 Background: A major engine overhaul restores the mechanical integrity and performance to the same levels as a newly purchased engine and is recommended after 30,000 hours of engine operation. Each overhaul resets the Time between Overhaul (TBO) cycle. An engine overhaul is essential to continuing maximum engine performance, availability and reliability. The engine will be renewed under Solar's Overhaul Exchange Program which is designed to minimize operational downtime. Under this program, the major engine components are replaced rather than remanufactured and then reinstalled. When the remanufacturing of the original components is eliminated from the overhaul process, the schedule is improved. The exchange components come from a pool of new and remanufactured parts that are of the same form, fit and function. These replacement parts are based on Solar's latest design and technology enhancements. The costs shall include all direct/indirect costs, labor, travel and supervision to complete the following. CONTRACTOR REQUIREMENTS 3.0 Technical Requirements/Tasks: ENGINE OVERHAUL The major components of a gas turbine engine overhaul for the Centaur 40 are listed below under the Scope of Supply. The objective of the Solar's Major Overhaul process is to provide an engine that meets the same quality and performance standards as a new engine and extends the next duty cycle to its maximum length. Aerodynamic, thermal, and mechanical internal configurations of the engine are upgraded to the most recent designs, which includes improvements that increase the reliability, durability, efficiency, and maintainability of the engine. Components that can complete another full duty cycle before the next overhaul are restored to original tolerances, which provide reliability at a reasonable cost. To ensure that each engine meets its design specifications, every overhauled engine component (as described in the Scope of Supply below) is tested on a fully instrumented facility skid with either a water-break dynamometer or generator. Material handling and work processes are consistent with and are certified to ISO-9002 and MRPII Class A practices. Exchange Gas Turbine Engine Overhaul The exchanged engine is composed of new and remanufactured components. Solar Turbines certifies that the finished product has been manufactured to Solar's stringent quality control standards and that the material being delivered conforms to all Solar specifications, drawings, and conditions. Under normal operating conditions, the customer can expect the engine to operate for 30,000 hours, or more depending on the engine model and its condition, before it needs another overhaul. Solar's Major Overhaul process is divided into the following phases: Core Disassembly Inspection Component Disposition Remanufacturing Assembly Testing Borescope Inspection Preparation for shipment Core Disassembly Solar Turbines shall disassemble the gas turbine down to the component level. Solar Turbines shall prepare an Equipment Condition Report that provides an overview of the condition of the core engine as it was received and provide that to the Owner. The purchaser or purchaser's designated representative is provided access to Solar's Overhaul facilities to observe the disassembly, on a non-interference basis, and in accordance with Solar's schedule. When requested, a more extensive analysis of failed or damaged components can be performed at an additional cost. Inspection Solar Turbines shall clean all of the parts, check parts for correct tolerances, and, where appropriate, put parts into nondestructive testing (NDT) to determine surface and subsurface material imperfections on critical, highly stressed turbomachinery components. This process follows Solar's Overhaul Inspection Standards. Solar shall also perform a series of visual and dimensional checks, as well as NDT methods that include but are not limited to: Magnetic Penetrant Inspection (MPI) Fluorescent Penetrant Inspection (FPI) X Ray imaging Component Disposition During this phase, Solar shall inspect engine components and either accept or reject components based on Solar's Overhaul Inspection. Standards criteria; Accepted components are sent to various Solar facilities and/or outside vendors for remanufacturing and reconditioning. Remanufacturing All suitable components are remanufactured to strict acceptance and repair limits that are controlled by the Solar Engineering Group. These acceptance and repair limits are determined by Solar standards. All components are returned to as-new condition and support overall engine durability. Operations include but are not limited to: Complex Machining Thermal Spray TIG Welding Vacuum Brazing CMM Inspection Laser Welding Electron Beam Welding Diffused Aluminide Compatible Alloy Brazing Coatings - SermeTel® The overhaul process shall incorporate the most recent design changes and manufacturing procedures that increase the reliability, durability, efficiency, and maintainability of the engine, all of which extend the next duty cycle to its maximum length. After the remanufacturing process is completed, the components are put in general inventory stores and are used as required to support subsequent equipment assembly. Assembly As the original equipment manufacturer (OEM), Solar applies Engineering Group-controlled design standards to all assembly processes to ensure mechanical integrity and performance of the engine and its components. Solar shall exchange equipment that is assembled from a pool of new and/or remanufactured components. Solar shall provide factory testing per Solar's original engine test specifications. The acceptance test for the engine is done on a facility test stand in accordance with Solar's specifications and the final report(s) shall be turned over to Owner at the end of the test(s). The test shall include the engine drives a water-break dynamometer or generator, which enables Solar to measure all aspects of engine operation and performance. The acceptance test shall include the following: Turbine power and heat rate (thermal efficiency) Turbine temperature measurements Vibration levels and spectra Emissions levels SoLoNOx or WetNOx control setpoints (when applicable) Bearing oil flows, pressures, and temperatures Seal airflows and pressure Engine compressor discharge pressure Thrust bearing temperatures Acceptance test data shall be reviewed and approved by the Solar Test Engineering Group and the Product Engineer and submitted to the customer. Borescope Inspection After the acceptance test, Solar shall perform a borescope and external inspection to ensure the equipment is in optimal condition. A borescope shall be inserted into several ports of the engine to examine blades in the compressor and hot sections of the turbine, and to confirm there are no internal oil leaks. External components such as fittings, fuel lines, probes and wires shall also inspected. Preparation for shipment Once the engine is fully borescoped, Solar shall install the additional equipment such as Accessory Gearboxes, Reduction Gearboxes and/or Collectors in the overhauled engine. Solar shall also install Coupling hubs, Variable Guide Vane covers and insulation blankets at this point. Solar shall create and install data tags in the overhauled units and the test report is attached. During this step, Solar shall ensure that all open ports are covered and plugged. In addition, loose ship kits that contain all the consumable hardware needed to install and connect the major assembly into the package are included. Finally, the overhauled unit is packaged per customer requirements and then is ready to ship. Equipment Serial Number Reuse Refer to Equipment Serial Number Reuse (PIL 237) for details about the methods available to reuse equipment serial numbers. Scope of Supply Gas Producer (GP) Gas Producer Loose Ship Kit Reduction Gear Box (RGB) Reduction Gear Box Loose Ship Kit 4.0 Government Furnished: The work will be performed on the North side of Building 154 Central Utility Plant during normal business hours. The contractor will be granted access by utility plant employees as needed. Solar and any representatives performing work onsite will be required to provide a minimum 48 hours advance notice of any individuals coming onsite and provide the individuals name, and company they work for. All individuals accessing the site shall abide by USDA site rules and regulations. 5.0 Deliverables / Schedule: The repairs will be completed and the Combustion Turbine and Generator will have been tested and made ready for normal service by June 1st, 2020. The result of this market research will contribute to determining the method of procurement. The applicable North American Industry Classification System (NAICS) code assigned to this procurement is 333611 with a size standard of 150 EMP There is no solicitation at this time. This request for capability information does not constitute a request for proposals; submission of any information in response to this market survey is purely voluntary; the government assumes no financial responsibility for any costs incurred. If your organization has the potential capacity to perform these contract services, please provide the following information: 1) organization name, address, email address, website address, telephone number, and size and type of ownership for the organization; and 2) tailored capability statements addressing the particulars of this effort, with appropriate documentation supporting claims of organizational and staff capability. If significant subcontracting or teaming is anticipated in order to deliver technical capability, organizations should address the administrative and management structure of such arrangements. The government will evaluate market information to ascertain potential market capacity to 1) provide services consistent in scope and scale with those described in this notice and otherwise anticipated; Based on the responses to this sources sought notice/market research, this requirement may be set-aside for small businesses or procured through full and open competition, and multiple awards may be made. Telephone inquiries will not be accepted or acknowledged, and no feedback or evaluations will be provided to companies regarding their submissions. Submission Instructions: Interested parties who consider themselves qualified to provide the above listed product are invited to submit a response to this Sources Sought Notice by 20 February 2020 10:00 CST. All responses under this Sources Sought Notice must be emailed to [email protected]. If you have any questions concerning this opportunity, please contact: [email protected].