FY19_AE1107C_CIP_SOW_RFP_Final.docx

DOCX document 77 KB Posted

Attached to
CY19 AE1107C Engine CIP
Solicitation number
19-002
Issued by

About this file

SOW

View the file

Other files

File Type Posted
FY19_AE1107C_CIP_CDRL_Final_Signed_-_BM_-_MD.pdf PDF

On GovTribe

Work with this file

  • Download the original file
  • Contacts named in this file
  • Similar government files
  • Ask GovTribe AI about this file

Text version

FY19 STATEMENT OF WORK

FOR

AE 1107C ENGINE COMPONENT IMPROVEMENT PROGRAM

Table of Contents

1.0Scope4
2.0Requirements4
3.0Engineering and Program Status Reviews5
4.0Engineering Project Descriptions6
4.1AE 1107C CIP Program Management6
4.1.1Scope6
4.1.2Requirements6
4.1.3Deliverables7
4.2AE 1107C CIP Small Tasks8
4.2.1Scope8
4.2.2Requirements8
4.2.3Deliverables8
4.3Analytical Condition Inspection (ACI) Program9
4.3.1Scope9
4.3.2Requirements10
4.3.3Deliverables12
4.4AE1107C Inconel 718 Power Turbine Wheels Spin Pit Test14
4.4.1Scope14
4.4.2Applicable Documents14
4.4.3Engineering Tasking14
4.4.4Deliverables17
4.5FADEC Bench Support18
4.5.1Scope18
4.5.1.1Background18
4.5.1.2Ground Rules18
4.5.2Requirements18
4.5.3Deliverables18
5.0List of CDRLs19
6.0Acronym List20
APPENDIX A21

1.0 Scope The Component Improvement Program (CIP) provides for contractor engineering and test support to address service and production related operational condition impacts and support concerns, to reduce engine operating and support costs, and to address electronic parts obsolescence issues. The effort will be directed at improving engine safety, reliability, maintainability, average time on wing, durability, operability, supportability, life management and life cycle cost savings.

The scope in this SOW is intended for the FY19 budget with a period of performance of 4/1/2019 – 12/31/2019.. The Contractor and Government representatives should collaborate on the scope that can be completed within calendar year 2019 to limit the scope of each EPD appropriately.

2.0 Requirements

The statement of work for the Component Improvement Program is a series of projects knows as Engineering Project Descriptions or EPD’s. Each EPD is a standalone project with unique cost, schedule, and deliverable(s). Efforts may include hardware redesign, overhaul/repair technique design, support equipment/tooling design, hardware modifications, and hardware analytical condition inspections, as required. The following is a list and short description of the proposed projects for FY19. The complete EPD for each project is in section 4.0.

FY19 Project List

EPD or Task # and Title
Project Overview
1
AE 1107C CIP Program Management

The scope of this EPD covers the overall program management of CIP efforts including but not limited to: kick-off meeting, EPD planning and decision reviews, yearly closeout meeting, financial reporting of each EPD, CIP proposal development.

2
AE1107C Small Tasks
Execute up to three (3), mid-contract, CIP efforts on emerging issues.
3
ACI Program
Analytical Condition Inspections (ACIs) are necessary to discover potential engine failure modes through rigorous inspection of fleet deteriorated hardware. The FY19 effort will focus on an engine removed for corrosion.
4
AE1107C Inconel 718 Power Turbine Wheels Spin Pit Test
This EPD defines the scope for the design, fabrication, and assembly of test hardware for conducting a LCF spin pit test and support for developing the test plan.
5
FADEC Bench Support
The EPD defines the scope for 2019 FADEC bench support.

3.0 Engineering and Program Status Reviews

The contractor shall conduct and facilitate two informal engineering and program status reviews per year as scheduled by mutual agreement between the contractor and government Technical Representatives. These informal reviews will provide a forum for the government and contractor technical and contracting managers to address technical, financial, and procurement issues. Any changes agreed upon at the review that affect scope and funding are not valid until submitted and approved by the respective Contractor and Government Contracting Officers in writing. The Government and Contractor should work together to schedule Technical Interchange Meetings (TIMs) (MissionCare funded) and CIP Reviews (CIP funded) to be held at the same location and on adjacent dates. This will allow sufficient time to discuss and manage programs covered by CIP funding

4.0 Engineering Project Descriptions

This section lists the individual engineering project descriptions (EPDs) that the contractor will use to develop the CIP proposal.

4.1 AE 1107C CIP Program Management

4.1.1 Scope

This Statement of Work (SOW) defines the effort required to execute Air 4.4 funded Component Improvement Program (CIP) program management related tasking.

4.1.1.1 Background

Program Management tasking includes things such as: Draft SOW, ROM and Proposal development, planning meetings and financial management, and reporting. The goal is to provide coverage for program management activities that allow for execution of a process as similar to the standard Air 4.4 CIP process as possible. Program management should also cover necessary communication with the Government to provide program execution plans, status of program execution, identify program deficiencies and associated corrective action, and address any other contractual concerns.

4.1.2 Requirements

4.1.2.1 CIP Program Management

The Contractor shall prepare minutes of the twice-annual CIP Review Meetings detailed in Section 3.0 above in accordance with CDRL A001.

The Contractor shall provide a monthly status report (in accordance with CDRL A002) to the Government that encompasses all on-going CIP EPDs covered in this SOW, on-going EPDs from the previous year’s CIP contract, and the following three projects, which are funded through CIP:

1. AE 1107C Lifing Analysis Update

2. Rolls-Royce Support of OSU Sand Rig Ignestion Testing

3. Commercial Catalogue Procurement of Test Cell Engine Hardware The format shall be compatible with Microsoft Office 2010, unless otherwise defined. At a minimum, these reports shall include:

1. A financial breakdown (expended vs. planned) of current accounting period totals, cumulative totals to date, and estimate at completion.

2. A summary of contract status with period of performance dates, present contract spend, and current contract funding amounts.

3. Current status of EPD projects, to include:

a. Technical trade-offs being considered

b. Potential risks to the project and mitigations of risk

c. Upcoming reviews and milestones

d. Summary of technical work performed

4.1.2.2 CIP Proposal Development

Following acknowledged receipt of the proposal by the Contrator’s Contracts Officer, the Contractor shall provide a response to the Governement within 14 days indicating whether the Contractor will submit a bid or will choose to “no quote.” The Contractor should then provide a proposal response to the Government within 90 days of the initial response.

Under the scope of the CIP Program, the Contractor shall participate in the development of potential projects that address non-design inherent or operational issues. The list of projects should align with the platform goals set in the NAVAIR Engine Management Plan (EMP).

The Contractor shall participate in development of predicted metrics impacts and technical improvement input related to return on investment for projects selected by the Government for further investigation.

4.1.3 Deliverables

The following items shall be delivered to support program management:

1. CIP Review Meeting Minutes (CDRL A001) for the following meetings:

a. Kick-off

b. Review Meeting #1

c. Review Meeting #2

d. Close-out

2. Monthly Status Report (CDRL A002)

4.2 AE 1107C CIP Small Tasks

4.2.1 Scope

This SOW defines the effort required to execute three (3) AIR 4.4 funded Component Improvement Program (CIP), mid-contract, emerging efforts.

4.2.1.1 Description

AIR 4.4 CIP is negotiated and agreed upon in a yearly cycle. Once the contract is initiated the only way to change work scope is through a time consuming contract modification. The goal of this project is to allocate resources to react quickly to emerging issues that arise after the contract initiation without performing a contract modification. The efforts in the EPD are event driven, as the tasks to be performed cannot be defined up front. Definition of proposed tasks will be submitted by NAVAIR via Engineering Coordination Memo (ECM) for authorization prior to starting work. Agreement on the individual small task Statement of Work shall be reached between the Government and Contractor prior to starting work. Contractor refusal of a requested small task shall be documented with explanation via ECM.

Small tasks that are agreed upon will be managed as a normal EPD, with specific Statements of Work, program plan, deliverables, and cost estimates. Rolls Royce shall be directed to perform work through a formal ECM written by the BDE and coordinated with the Systems Engineer and COR. Small tasks may result in a completed engineering effort or a dedicated EPD in the next CIP contract.

4.2.2 Requirements

1. Preparation of small task proposals shall be funded by the Program Management EPD.

2. Small tasks shall be authorized by a formal coordination memo from NAVAIR AE 1107C BDE

3. Deliverables for each small task shall be formalized in the coordination memo and agreed to between the Government and Contractor prior to work beginning.

4.2.3 Deliverables

The following items shall be delivered in support of this Statement of Work, as required and outlined in the agreement of work ECM.

1. Cost and schedule estimate to complete small task (CDRL A003).

2. Final Report which may contain the following as required by each specific small task: Project objective and success criteria, Failure Mode and Effects Analysis, root cause analysis, project requirements preliminary qualification requirements, potential solutions for a trade study, down-selection criteria for a trade study, project risks and mitigation strategies, summary of technical work completed (CDRL A004).

4.3 Analytical Condition Inspection (ACI) Program

4.3.1 Scope

This SOW defines the effort required to conduct an Analytical Condition Inspection (ACI) on a field return AE 1107C engine. This project will allow the Government and Contractor to develop an ACI plan for current and future ACIs. The ACIs will take place at the repair facility of the Contractor’s choice.

4.3.1.1 Background

The first ACI funded through this EPD occurred in 2016 at RRESO (Rolls-Royce Engine Services – Oakland) on an engine removed for low power. This was the first opportunity to formulate a formal ACI plan for the AE 1107C engine. It was noted during the ACI that some steps were skipped due to the order in which they were organized in the ACI plan. The team will mitigate the risk of missing steps moving forward by formulating and agreeing to a formal ACI plan.

4.3.1.2 Applicable Documents

1. Contract Number: N00019-13-G-0011 BOA (FAR PART 15)

2. AE 1107C Engine Repair Manual – CSP31006

3. Model Specification 937A

4. EDNS04000080814 – Low Power ACI AE 1107C Assessment CAE130670

4.3.1.3 Ground Rules and Assumptions

1. The Government will identify the engine upon which to conduct an ACI no later than two (2) weeks from removal of the engine from a V-22.

2. The ACI shall be conducted in the presence of RRC, NAVAIR, DCMA and/or any other approved US Government/Government Support personnel. NAVAIR will dictate government attendees and attempt to restrict participation to no more than five (5) attendees per ACI.

3. The standard engine teardown is included by MissionCare™ or appropriate contract vehicle as applicable.

4. Start time of the ACI is dependent on other Engineering Investigations, availability at the repair facility, and the identification/availability of a suitable engine by NAVAIR. It is expected for repair facility activities to begin on, or before April 1, 2019. Considering the summer timeframe, the following should not be an issue, but no ACI activities will be scheduled for the repair facility during the months of October through December.

5. The ACI engine and reusable parts will be released for repair within 90 days of the initial teardown inspection, and the repaired engine then returned to fleet service

6. Final inspection report (which is CDRL A006) content and format will be based on the report submitted for the previous ACI (EDNS04000080814).

Test and Evaluation

1. The Contractor shall take maximum advantage of the Contractor’s facilities, equipment, personnel, inspection techniques, and the procedures contained in the AE 1107C Engine Repair Manual in performance of this SOW unless otherwise specified. The Contractor shall take maximum advantage of processes and tasking to be performed during the normal course of the ACI engine’s repair.

Test Equipment/Systems

1. The Contractor shall use an AE 1107C engine test stand that:

a. Is calibrated per Engine Model Specification 937A section 4.7.4.6

b. Has airflow measurement capability.

2. The Contractor shall provide substantiation of test cell calibration IAW CDRL A006.

ACI Photography at Contractor’s Facility

1. Photographs may only be taken by Rolls-Royce personnel. Use of any photographic equipment (including cameras on cell phones) by visitors is prohibited.

2. Photographs will only be transmitted per the Post-Inspection Report, which may not include all photographs taken, but only photos selected for inclusion in the report.

4.3.2 Requirements

4.3.2.1 Engine Testing Requirements

The Contractor shall:

1. Perform a cursory, visual engine inspection including borescoping and record results.

2. Install the engine on the calibrated test stand including instrumentation required to measure compressor efficiency, HPT and LPT efficiency, and whole engine performance.

3. Execute the performance run on the calibrated test stand per engine manual subtask 72-00-00-760-011. Record all data referenced in Table 1321 for each tested power setting.

4. Assess and record the performance run data, compressor efficiency, HPT and LPT efficiency, and whole engine performance at each tested power setting IAW CDRL A006. Reporting will be of same format and content as delivered with previous ACI report.

5. Remove engine from calibrated test stand and move to disassembly area.

6. Provide Government personnel access to observe all of the activity listed in this section, while following all Health, Safety, and Environmental rules of the repair facility.

4.3.2.2 Component Inspection Requirements

The Contractor shall:

1. Host an ACI Planning Conference as coordinated with NAVAIR (Expectation is no later than 1 month after contract award) to ensure proper teardown and inspection plans have been identified, documented, and are in place prior to induction of the engine into the Contractor’s facility. The meeting should at a minimum cover ACI strategy, tasking in Appendix A, and guidance on creation of the ACI Event Procedure (CDRL A005). This meeting may be virtual or in-person.

2. Disassemble the engine to the extent that turbine and compressor blade tip radii measurements can be completed (ref. engine manual tasks 72-35-01-300-801 and 72-52-03-000-801 in Appendix A below).

3. The Contractor shall complete turbine and compressor blade tip radii measurements prior to full parts / components layout (ref. engine manual tasks 72-35-01-300-801 and 72-52-03-000-801 in Appendix A below).

4. Fully disassemble the engine and layout all engine parts / components in a Contractor identified space for a 3-day period. All parts / components are expected to be in un-cleaned, field return condition.

5. Upon parts / components release by the lead government engineer on-site or the expiration of the 3-day layout period, perform all remaining inspection and documentation requirements per Appendix A.

6. Provide six (6) compressor blades from each of the 14 compressor stages to the government for additional lab analysis inspection efforts after all remaining inspections and documentation requirements per Appendix A are complete. This hardware is expected to be released to the government at no additional cost to the contract per conversations held between NAVAIR and Rolls-Royce July 19, 2017. In exchange, NAVAIR will provide Rolls-Royce a copy of any analysis report produced regarding the blades, and an accounting of the final disposition of all parts provided.

The Contractor shall at minimum provide Government personnel access to observe the activities listed in items 1, 2, 3, and 4 above.

4.3.2.3 Chit Management Requirements

The Government engineers may write chits for further action. The chits shall identify the part (s) for further action, the serial number (if applicable), and the issue / question / comment. These actions may include:

1. Requests for information part (s) condition or discrepancy such as causes or effects.

2. Requests to hold a part or component for further testing or analysis. The Contractor shall assume that the Government shall fund these actions separately.

The Contractor shall:

1. Manage and respond to all chit requests; chit requests will only be provided by the lead government engineer on-site.

2. Hold all parts with open chits until the associated chit has been closed and has been held for 90 days from the time of initial teardown inspection for any follow-up questions, but not to exceed the period of performance.

Additionally, during the previous ACI of 2016, NAVAIR and Rolls-Royce agreed on various types of chits and the appropriate responses in somewhat more detail. All formal chits will be submitted to Rolls-Royce via the electronic coordination memo system.

1. “Type A” chits are those deemed by Rolls-Royce as easy, quick-answer type questions from NAVAIR. These chits will be worked as soon as practical without negatively impacting other ACI activities and coordination.

2. “Type B” chits are those deemed by Rolls-Royce to require more investigation, including requiring additional analysis or testing, or the gathering and synthesize the data not readily available. These items are considered not within the scope of the ACI inspection. These chits will be held pending a separate contract from NAVAIR (if desired) specifically for dispositioning these chits.

3. Rolls-Royce assumes the overall number of chit requests, and the number of “Type A” chit requests during this ACI will not be significantly different than during the 2016 ACI.

4.3.2.4 Inspection and Chit Response Documentation Requirement The Contractor shall:

1. Provide a report that contains the testing results, chit responses, and inspection results required by Appendix A IAW CDRL A006.

4.3.3 Deliverables

The following items shall be delivered to support this ACI program:

Deliverables Related to ACI-Corrosion (2019)

Deliverable Title
From
To
Detailed Description & Format
Date or Relative Date
Engine Selection
NAVAIR
Rolls-Royce
NAVAIR will select a recently removed engine due to Corrosion for the ACI, and notify Rolls-Royce of the selected engine's serial number by ECM
Within ~2 weeks from removal from a V-22, and already at the Rolls-Royce overhaul facility
ACI Event Procedure Report
Rolls-Royce
NAVAIR
Following a joint Rolls-Royce/NAVAIR ACI Planning Conference, Rolls-Royce will produce an ACI Event Procedure report in EDR format outlining the order and procedures expected for the ACI. It is not the intent of this document to repeat all the detailed inspection procedures of the engine manual, but to chart a plan/order for the proper collection of appropriate measurements during the various stages of the engine teardown.
The ACI Event Procedure Report is CDRL A005. The ACI Planning Conference is planned to be held following contract award and engine selection, and approximately 4-6 weeks prior to the main ACI inspection event. The ACI Event Procedure Report is expected to be delivered two weeks prior to the ACI inspection event.
Compressor Blades
Rolls-Royce
NAVAIR
Rolls-Royce will send NAVIAR 6 blades from each of the 14 compressor stages for follow-on lab analysis performed by NAVAIR
Following final inspection and release of the parts from ACI. Parts are expected to ship by the first week of July.
Compressor Blades Analysis Report
NAVAIR
Rolls-Royce
Following NAVAIR's analysis of the compressor blades provided by Rolls-Royce, NAVAIR will provide to Rolls-Royce a detailed report of their findings with supporting evidence and will document the final disposition of the blades
NAVAIR performing the follow-on analysis, gathering data, and providing a report should be accomplished prior to 14 December 2019.

Test Stand Certification

Rolls-Royce
NAVAIR
Rolls-Royce will provide a copy of the current "Certificate of Authority" demonstrating the Test Cell is approved and current
A copy of the certificate will be included in CDRL A006 ACI-Corrosion Post Inspection Report, scheduled for delivery on Sept 14, 2019

Installed Performance Trends

Rolls-Royce
NAVAIR
To the degree performance data from the selected engine is available, Rolls-Royce will provide a Performance Trend chart (Engine Percent Power v. Engine Run Time)
Chart will be included in CDRL A006 ACI-Corrosion Post Inspection Report, scheduled for delivery on Sept 14, 2019
As Received Engine Performance
Rolls-Royce
NAVAIR
Rolls-Royce will run a performance test on the selected engine in the "as received" condition and provide as received performance engine data in the same format as previously provided
Data will be included in CDRL A006 ACI-Corrosion Post Inspection Report, scheduled for delivery on Sept 14, 2019
Chit Management
The general Chit process is provided in the SOW and will follow the same process exercised during ACI#1 of late 2016

Post Inspection Report

Rolls-Royce
NAVAIR
Rolls-Royce will produce a ACI-Corrosion Post Inspection Report in the same format as previously provided for ACI#1 in 2017
Report is the CDRL A006 ACI-Corrosion Post Inspection Report, scheduled for delivery on Sept 14, 2019

4.4 AE1107C Inconel 718 Power Turbine Wheels Spin Pit Test

4.4.1 Scope

This Statement of Work (SOW) defines the effort required for a spin pit test for the AE1107C Inconel 718 Power Turbine Wheels.

4.4.1.1 Background

On 19 August 2016, Rolls-Royce communicated to NAVAIR its intention to submit as a Type II AEM Inconel 718 3rd and 4th Stage Power Turbine Wheels. NAVAIR reviewed the presentation materials and determined that the qualification plan was deficient relevant to Engine Model Specification 937A. In subsequent communications between NAVAIR and Rolls-Royce, both parties agreed to additional testing, an engine endurance test (completed and report approved by NAVAIR 7/19/2018), and a spin pit test, to support airworthiness certification of the Inconel 718 Power Turbine Wheels by NAVAIR. The spin pit test is intended to validate the 20,000 mission cycles Chapter 5 lives of the PT wheel assembly. The test will be conducted by Rolls-Royce in the spin test facility located at Rolls-Royce, Indianapolis.

4.4.2 Applicable Documents

1. RRC-AE1107C-2016-056: Transmittal of PT Wheel Redesign Material

2. NAVAIR-AE1107C-2016-039: PT Wheel Testing Rationale

3. RRC-AE1107C-2018-051 PT Wheel Type 2 Concurrent Documentation

4.4.3 Engineering Tasking

4.4.3.1 Test Planning Requirements

The Contractor shall provide the Government a test plan, with the appropriate number of cycles to achieve a -3 sigma 95% confidence cleared LCF crack initiation life, at the critical location(s) of the PT Wheel Assembly, (-3 sigma 50% confidence LCF life at all other competing features) for both AE2100 and AE1107C engine models.

The Contractor shall support a joint Government-Contractor Test Readiness Review (TRR). The Government and the Contractor shall each appoint a TRR co-chair from outside the project team to provide approval to proceed with the test. A successful TRR is required to execute the test.

4.4.3.2 Test Hardware Requirements

The Contractor shall use Contractor’s standard specifications to design a spin pit arbor for a heated, isothermal, Low Cycle Fatigue (LCF) vacuum spin test on one (1) AE1107 3rd and 4th stage power turbine rotor assembly that interfaces with the Spin Pits at the Contractor’s facility.

The test rotor shall consist of a 3rd stage and 4th stage rotor assembly with adaptive tooling (arbor and vertical drive spindle) to connect the test article to the spin test facility air motor.

The Contractor shall incorporate a catcher system to prevent damage to the test rotor resulting from a drive spindle failure or blade release.

The Contractor shall be responsible for design of the static hardware (oven) required to heat and control the test rotor temperature.

The Contractor shall provide for the purpose of conducting LCF testing the following items as a test rotor assembly with the Contractor designed arbor and vertical drive spindle:

1. Inconel 718 Stage 3 Power Turbine Wheel (P/N: 23091377)

2. Inconel 718 Stage 4 Power Turbine Wheel (P/N: 23091379)

3. 78 Stage 4 Power Turbine Blades (P/N: 23091301)

4. Power Turbine Locking Ring (P/N: 23053355)

5. 10 Slab Head Machine Bolts (P/N: 23053107

6. Thrust Seal (P/N: 23072476)

7. 12 Tee Head Bolts (P/N: MS9432-08)

8. 12 Self Locking Hex Nuts (P/N: MS21043-3)

9. Rear Power Turbine Shaft (P/N: 23057927)

10. 3rd to 4th Stage Turbine Spacer (P/N: 23050918 or 23089140)

11. 84 Stage 3 Power Turbine Blades (P/N: 23089793)

12. 6 each 3rd Stage Turbine Balance Weights (P/N: 23038853-1,2,3,4,5,6,7 & 8)

13. 12 Tee Head Bolts (P/N: MS9432-06)

14. 12 Self Locking Hex Nuts (P/N: MS21043-3)

15. 4th Stage Turbine Balance Weights (P/N: 23035795-4,5,6,7,8 & 9) The Contractor shall provide spare test hardware as required for tear down, inspection, and rebuild of test article during testing.

The Contractor shall ship the test rotor assembly to the following location at the conclusion of the test:

22229 Elmer Road Patuxent River, MD 20670

4.4.3.3 Inspection Requirements

The Contractor shall perform the test hardware teardowns, inspections, and assemblies. The Government will be invited to observe the inspections at 1/4th test duration intervals at the Contractor’s facility.

The Government may send representatives to witness the Spin Pit Testing during each inspection cycle and each of the inspections. Inspection cycles are defined as the period of time between inspections or 1/4th test duration.

4.4.3.4 Documentation Requirements

The Contractor shall provide a test plan (CDRL A007). The test plan shall include:

· Purpose of test

· Scope of test

· Description of test article

· Test setup

· Description of test facility to include spin chamber, drive system, speed measurement, speed control system, drive spindle vibration monitoring system, temperature control system, data acquisition system, safety shutdown system, and support equipment

· Description of test rotor installation into spin pit with layout drawing

· Description of adaptive tooling (arbor) and spin pit interface details

· Description of test rotor heating method and hardware

· Description of test rotor catcher system

· Instrumentation and data acquisition

· Instrumentation parameter list with parameter measurement accuracy, measurement range, operating range, test shutdown limit value, and data acquisition recording sample rate

· Description of speed measurement instrumentation and NIST traceable calibration procedure

· Description of test temperature measurement instrumentation and NIST traceable calibration procedure

· Description of spindle vibration measurement instrumentation

· Description of LCF cycle counting instrumentation

· Key input parameters that determine the LCF cycle of the test article; items include but not limited to the following:

· Most severe/limiting mission that drives the LCF cycle

· Engine stresses at most severe/limiting mission

· Equivalent rig stresses at most severe/limiting mission

· Minimum number of crack free cycles needed to meet life requirements of both AE2100 and AE1107C engine models

· Maximum rig speed needed to match stresses from most severe/limiting mission

· Minimum rig speed to complete a cycle

· Description of LCF cycle with rpm tolerances and cycle time

· Inspection intervals at ¼ interval of the total planned testing period

· Inspection methods

· Criterion to determine to continue the test prior to starting the next interval

· Success criteria for evaluation of the wheels at the end of the test

The Contractor shall provide briefing materials (CDRL A008) and support a Test Readiness Review with the Government. The TRR materials shall include the following in addition to the content from the test plan:

· Stress analysis results of the arbor and adaptive tooling specifically designed for the test to ensure test article is fit for purpose

· Stress analysis results of the entire test article

· Operational test limits and associated operator actions The Contractor shall provide twice a week test reports via email to the AE 1107C BDE (Monday and Thursday) with the number of cycles executed since the previous report, the total number of cycles executed, and any anomalies that occurred during testing.

The Contractor shall provide a final test report (CDRL A009). The final test report shall include the full content from the test plan and the test readiness review in addition to the following:

· The total number of cycles executed and the total test time

· Inspection results from the pre-test inspection, the ¼ test interval inspections, and the post-test inspection

· Any deviations from the test plan

4.4.4 Deliverables

The following items shall be delivered in support of this Statement of Work:

1. Test Plan (CDRL A007)

2. Test Readiness Review Materials (CDRL A008)

3. Final Test Report (CDRL A009)

4. Test Rotor Assembly

4.5 FADEC Bench Support

4.5.1 Scope

This SOW defines the effort to provide 2019 support of the FADEC Bench at NAVAIR’s Patuxant River Manned Flight Simulator facility.

4.5.1.1 Background

The FADEC Bench upgrade is a 2018-2019 project expected to complete approximately 9/30/2019. This task will provide on-going technical support to the FADEC Bench at NAVAIR’s Patuxent River Manned Flight Simulator facility with an increase in support following the installation of the upgrade.

4.5.1.2 Ground Rules

The responsibility for maintaining the software bench in good working order remains with NAVAIR. The Contractor will provide technical assistance with items related to software specifically from the Contractor, not items of outside sourced software or hardware. As best it can be discerned, issues related to other NAVAIR provided software/hardware/ equipment or items supplied by other vendors will not be within the scope of this effort.

Requests for support will be directed to Contractor CIP contract manager who will direct the inquiry to the appropriate specialist.

4.5.2 Requirements

105 hours of FADEC bench technical support (As with 2018 Test Cell support, for example, the 105 hours will be based on an estimate of the proper department skilled to best answer any given question). 10 hours per month from April 1, 2019 – September 30, 2019 followed by 15 hours per month from October 1, 2019 – December 31, 2019. The variance in rates between departments may result in actual available hours for the funding being somewhat different than the 105 hour figure.

4.5.3 Deliverables

Monthly FADEC bench support usage to be included in the Program Management Monthly Status Reports per Section 4.1.3 above. (CDRL A002)

5.0 List of CDRLs

Relevant EPD
CDRL List
Paragraph Located
AE 1107C CIP Program Management
1. CIP review meeting minutes (CDRL A001)

2. Monthly status reports (CDRL A002)

4.1.2.1 & 4.1.3 4.1.2.1, 4.1.3 & 4.6.3

Small Tasks
3. Cost and Schedule Estimate (CDRL A003)

4. Final small task report (CDRL A004) 4.2.3

ACI Program
5. ACI Event Procedure report (CDRL A005)

6. ACI corrosion post inspection report (CDRL A006)

4.3.2.2 & 4.3.3

4.3.2.1 & 4.3.3

AE1107C Inconel 718 Power Turbine Wheels Spin Pit Test
7. Test Plan (CDRL A007)

8. Test Readiness Review (CDRL A008)

9. Final Test Report (CDRL A009)

4.4.3.4 & 4.4.4

4.4.3.4 & 4.4.4

6.0 Acronym List

Acronym
Definition
Acronym
Definition
ACI
Analytical Condition Inspection
MFS
Manned Flight Simulator
BOA
Basic Ordering Agreement
OD
Outer Diameter
CDP
Compressor Discharge Pressure
OEI
One-Engine Inoperative
CDRL
Contract Data Requirements List
PSEF
Propulsion System Evaluation Facility
CDT
Compressor Discharge Temperature
RFP
Release For Proposal
CIP
Component Improvement Program
ROM
Rough Order of Magnitude
CVG
Compressor Variable Geometry
SEHV
Single Engine Height Velocity
EMP
Engine Management Plan
EPD
Engineering Project Description
TIM
Technical Interchange Meeting
HPT
High Pressure Turbine
IAW
In Accordance With
LPT
Low Pressure Turbine

APPENDIX A

The Contractor shall perform the full task as identified in the AE 1107C Engine Repair Manual for each task listed in Table 1 unless otherwise noted. Table 1 is organized as follows:

· Column 1 “Task” - identifies the AE 1107C Engine Repair Manual task number.

· Column 2 “Title” - identifies the task name.

· Column 3 “Quantity” - identifies stipulations on the quantity of applicable parts per engine with which to perform the full task and any additional scope.

· Column 4 “Perform Full Work Package Except For” - identifies any scope that is specifically not required.

· Column 5 “Perform In Addition To Work Package” - identifies any scope that is required to be performed in addition to the task as written in the AE 1107C Engine Repair Manual.

The Contractor shall also follow the assumption that Fluorescent Penetrant Inspection (FPI) is not required for any of the parts unless specifically noted in Column 5.

Table 1: Specific ACI Tasking

Task
Title
Quantity
Perform Full Work Package Except For:
Perform In Addition To Work Package:
72-00-51-200-801
Do the Inspection of the Gas-Generator-Turbine 1st-Stage Vane-and-Support Assembly
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist, need to annotate dimension, defect, crack, high metal dimensions, quantities, locations, and pictures for each WP element. 3. For Unwanted Material in Passages and Combustion-liner inner-seal ring air hole classify as light, moderate, or heavy.

72-00-52-200-801
Do the Inspection of the Gas-generator-turbine Rotor/Case and 2nd-stage Vane Assembly
All
1. Dimensional inspection not required.
1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist, need to annotate dimension, defect, crack, high metal dimensions, quantities, locations, and pictures for each WP element. 3. For Unwanted Material in Passages classify as light, moderate, or heavy.
72-00-57-200-801
Do the Inspection of the Power-turbine Assembly
All
1. Dimensional inspection not required.
1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element. 2. Regardless of whether or not serviceable limits exist, need to annotate dimension, defect, crack, high metal dimensions, quantities, locations, and pictures for each WP element. 3. For Unwanted Material in air holes, thermocouple passages, and rear turbine bearing support passages classify as light, moderate, or heavy .
72-25-03-200-801
Do the Inspection of the IGV Actuation Ring-and-Button Assembly
All
SUBTASK 72-25-03-230-001 FPI not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, chips, wear, fretting, and crack quantities, locations, and pictures for each WP element. 3. For SUBTASK 72-25-03-220-002 record dimensional inspection
72-25-05-200-801
Do the Inspection of the IGV Vane Actuation Arm-and-Ball Assembly
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, deformation, fretting, and crack quantities, locations, and pictures for each WP element.

72-25-15-200-801
Do the Inspection of the Inlet Housing Hub-flowpath Extension
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element. 2. Regardless of whether or not serviceable limits exist..Need to annotate defect, crack, high metal dimensions, quantities, locations, and pictures for each WP element.

72-25-21-200-801
Do the Inspection of the Compressor Air-Inlet Housing
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element.. 2. Regardless of whether or not serviceable limits exist..Need to annotate defect, crack, high metal dimensions, quantities, locations, and pictures for each WP element. 3. For paint missing classify as light, moderate, or heavy with pictures and location annotated.

72-25-33-200-801
Do the Inspection of the No. 2 Carbon-Seal Assembly
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element.. 2. Regardless of whether or not serviceable limits exist..Need to annotate wear, defects, and coke dimensions, quantities, locations, and pictures for each WP element.

72-25-33-700-801
Do the test of the No. 2 Carbon-Seal Assembly
All

1. Flow check carbon seal assembly prior to cleaning and annotate measurement.

72-25-35-200-801
Do the inspection of the No. 3 Carbon-Seal Assembly
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element.. 2. Regardless of whether or not serviceable limits exist..Need to annotate wear, defects, and coke dimensions, quantities, locations, and pictures for each WP element.

72-25-35-700-801
Do the Test of the No. 3 Carbon-seal Assembly
All

1. Flow check carbon seal assembly prior to cleaning and annotate measurement.

72-25-35-780-001
Do the flow test of the No. 3 carbon-seal assembly.
All

1. Flow check carbon seal assembly prior to cleaning and annotate measurement.

72-25-37-200-801
Examine the No. 4 Carbon-Seal Assembly
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element.. 2. Regardless of whether or not serviceable limits exist..Need to annotate wear, defects, and coke dimensions, quantities, locations, and pictures for each WP element.

72-25-37-220-001
Examine the No. 4 carbon-seal assembly.
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element.. 2. Regardless of whether or not serviceable limits exist..Need to annotate wear, defects, and coke dimensions, quantities, locations, and pictures for each WP element.

72-25-37-700-801
Do the Test of the No. 4 Carbon-Seal Assembly
All

1. Flow check carbon seal assembly prior to cleaning and annotate measurement.

72-25-37-780-001
Do the test of the No. 4 carbon-seal assembly.
All

1. Flow check carbon seal assembly prior to cleaning and annotate measurement.

72-25-42-200-801
Do the Inspection of the Stationary Labyrinth Spacer
All
1. Spacer and pilot diameter general inspection not required 2. FPI not required-subtask 75-25-42-220-002
1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element. 2. Regardless of whether or not serviceable limits exist..Need to annotate defect, and crack quantities, locations, and pictures for each WP element.
72-25-45-200-801
Do the Inspection of the Variable-Inlet Guide Vane
8 vanes for each stage including vanes designated as worst case by inspecting personnel

1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, bends, tears, pits, and crack quantities, locations, and pictures for each WP element. 3. For SUBTASK 72-25-45-220-002 only perform and record dimensional inspection on 8 evenly spaced vanes

72-30-00-200-801
Do the Inspection of the Compressor Assembly
All
2. SUBTASK 72-30-00-220-804 not required 3. SUBTASK 72-30-00-280-001 4. SUBTASK 72-30-00-220-002 Dimensional inspection of the compressor assembly not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, wear, fretting, and crack quantities, locations, and pictures for each WP element.
72-35-01-300-801
Repair the Compressor Rotor Assembly
All

1. Only measure and record blade tip radii (max, min, average) and runout for all stages as listed out in step G.(2)(f) under SUBTASK 72-35-01-320-001

72-35-03-200-801
Do the Inspection of the 1st- thru 14th-Stage Compressor Blades
8 Blades for each stage including blade designated as worst case by inspecting personnel
3. SUBTASK 72-35-03-220-003 dimensional inspection not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element. 2. Regardless of whether or not serviceable limits exist - need to annotate blunt radii, LE rollover and hooking, nicks, pits, defects, high metal, corrosion, roughness and crack quantities, locations, and pictures for each WP element. 3. SUBTASK 72-35-03-230-001 FPI only required for Stage 1 4. For SUBTASK 72-35-03-220-002 record dimensional inspection
72-35-03-100-802
Clean the 1st- thru 14th-Stage Compressor Blades
Items 1-3: 8 Blades for each stage including blade designated as worst case by inspecting personnel. Items 3-4: 4 Blades for each stage including blade designated as worst case by inspecting personnel.
1. SUBTASK 72-35-03-110-005 not required 2. SUBTASK 72-35-03-110-006 not required 4.SUBTASK 72-35-03-850-001 not required. Polishing of blades is not required
1. Annotate the degree of fouling/grime as light, moderate, heavy present on blade airflow surfaces including locations on both concave and convex sides 2. Only perform the micro-finish measurement portion of SUBTASK 72-35-03-220-001 and record for both concave and convex surfaces for 8 evenly spaced blades per stage. 3. Perform 3D scans for 4 rotor airfoils per stage and compare/overlay with nominal blades for each stage. 4. Document any anomolies in field returned geometry relative to print. 5. Document blade geometry deltas from print at 3 span-wise locations (root, mid-span, tip) including:

-Chord width -LE thickness -LE radius -Max thickness -TE thickness -TE radius -Camber distribution

72-35-23-200-801
Do the Inspection of the 1st-Stage Compressor Wheel
All
SUBTASK 72-35-23-230-001 not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non. for each inspectable element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, fretting, wear, pits, corrosion, and crack quantities, locations, and pictures for each WP element. 3. For SUBTASK 72-35-23-220-002 record dimensional inspection
72-35-25-200-801
Do the Inspection of the 2nd-Stage Compressor Wheel
All
SUBTASK 72-35-25-230-001 not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, fretting, wear, pits, corrosion, and crack quantities, locations, and pictures for each WP element. 3. For SUBTASK 72-35-25-220-002 record dimensional inspection
72-35-27-200-801
Do the Inspection of the 3rd-thru 5th-Stage Compressor Wheels
All
SUBTASK 72-35-27-230-001 not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, fretting, wear, pits, corrosion, and crack quantities, locations, and pictures for each WP element. 3. For SUBTASK 72-35-27-220-002 record dimensional inspection
72-35-29-200-801
Do the Inspection of the 6th- thru 13th-stage Compressor Wheels
All
SUBTASK 72-35-29-230-001 not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, fretting, wear, pits, corrosion, and crack quantities, locations, and pictures for each WP element. 3. For SUBTASK 72-35-29-220-002 record dimensional inspection
72-35-31-200-801
Do the Inspection of the 14th-Stage Compressor Wheel
All
1. SUBTASK 72-35-31-230-001 not required 2. SUBTASK 72-35-31-220-002 not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, fretting, wear, pits, corrosion, and crack quantities, locations, and pictures for each WP element.
72-37-03-200-801
Do the Inspection of the 1st- thru 5th-stage Actuation Ring-and-button Assembly
All
SUBTASK 72-37-03-230-001 FPI is not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, looseness, chips, and crack quantities, locations, and pictures for each WP element 3. Record dimensional inspections in SUBTASKS 72-37-03-220-002 and -003
72-37-05-200-801
Do the Inspection of the 1st- thru 5th-Stage Vane Actuation Arm-and-Ball Assembly
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, looseness, chips, fretting, and crack quantities, locations, and pictures for each WP element

72-37-13-200-801
Do the Inspection of the Upper and Lower Halves of the Compressor Case
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist..Need to annotate defect, crack, high metal dimensions, quantities, locations, and pictures for each WP element. 3. Measure diameter BK at each stage at 8 equally spaced locations. Annotate clocking position of measurement.

72-37-13-200-801
Do the Inspection of the Upper and Lower Halves of the Compressor Case
All
1. SUBTASK 72-37-13-230-003 FPI not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, missing coating, track coating grooving magnitude (qualitative), wear, pits, corrosion, and crack quantities, locations, and pictures for each WP element. 3. For SUBTASK 72-37-13-220-002 only perform and record DIA BK measurements at 8 evenly spaced circumferential locations for all stages
72-37-15-200-801
Do the Inspection of the 1st- thru 5th-Stage Actuating-Ring Connector Plate
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, high metal, scratches, and crack quantities, locations, and pictures for each WP element

72-37-17-200-801
Do the Inspection of the 1st- thru 5th-stage Compressor Inner-ring Segments
All
1. SUBTASK 72-37-17-230-001 FPI not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, missing coating, chips, areas of no grooving, and crack quantities, locations, and pictures for each WP element 3. Measure and record groove depth in 8 evenly spaced circumferential locations for both Area F and Area G (REF FIG 72-37-17-990-801) 4. Perform radius and runout measurements relative to the centerline of Area F and Area G inner-band coating areas (REF FIG 72-37-17-990-801) corresponding to the clocking location of the 8 groove depth measurements taken. Annotate clocking position of all measurements.
72-37-18-200-801
Do the Inspection of the Torquetube Assembly
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist..Need to annotate defect, crack, high metal dimensions, quantities, locations, and pictures for each WP element.

72-37-19-200-801
Do the Inspection of the 1st- thru 5th-Stage Compressor Variable Vanes
8 vanes for each stage including vanes designated as worst case by inspecting personnel
1. SUBTASK 72-37-19-230-001 FPI not required 2. SUBTASK 72-37-19-220-003 dimensional inspection not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, high metal, fretting, corrosion, erosion, and crack quantities, locations, and pictures for each WP element
72-37-21-200-801
Do the Inspection of the 6th- thru 13th-Stage Compressor Vanes
8 vanes for each stage including vanes designated as worst case by inspecting personnel
1. SUBTASK 72-37-21-230-001 FPI not required
1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist - need to annotate defects, airfoil erosion, missing coating, chips, areas of no grooving, and crack quantities, locations, and pictures for each WP element 3. Measure and record abradable coating groove depth in 8 evenly spaced circumferential locations 4. Record dimensional inspection measurements in SUBTASK 72-37-21-220-002 corresponding to the clocking location of the 8 groove depth measurements taken. Annotate clocking position of all measurements.
72-39-07-200-801
Do the Inspection of the Compressor Diffuser Assembly
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element. 2. Regardless of whether or not serviceable limits exist..Need to annotate defect, crack, high metal dimensions, quantities, locations, and pictures for each WP element. 3. For leaks, quantify the pressure loss.

72-39-15-200-801
Do the Inspection of the No. 5 Carbon-seal Assembly
All

1. Need to annotate whether the item is considered serviceable, repairable, or Non for each inspect-able element.. 2.

This is the start of the file's text. The full file is on GovTribe.

File details come from the government source that posted it.