FOUND IT!!!
I removed the hammer and instantly found the problem. A prior (and very appearent dumbass) someone removed the trigger spring and installed it upside down and all funkafied. The trigger was being held up by the pin and the spring was just flopping around. Now if it was me and I installed it that way I would be thinking ----Self, thats not right---springs arn't supposed to be loose. There was some tension from the spring but only at certain time of the trigger pull.
So heres my quess....
At times the trigger tension was too lose and allowed the disconnector to release the hammer which caused it to fire two rounds with one trigger pull.
After I CORRECTLY installed the spring both myself and the officer who is issued the rifle, greatly noticed a heaver trigger pull. I gave him a box of ammo and said "Make some brass". I'm hopefull this solves the problem.
And for those who are wondering.....
He never experienced this problem before because of old, out of date and lame training. Slow rates of fire at long distances. When I updated the training (close range with rapid fire) he noticed the problem. Heres a laugh.....he's been with the department for over 4 years!!! Who knows how long the spring had been installed incorrectly!!!
Funny thing is I used just about every check to make sure the rifles function properly, firing pin protrusion, head space go - no go gauge, function checks and a up close and personal inspection. I would have never guessed some knuckle head screwing up something so simple.
Thanks guys for the good advise!!!
(Now I'm thinking to myself, 22 other rifles in the department - how many more are incorrect?)