ENGINE_SOW.pdf

1.0 Introduction & Background

The National Aeronautics and Space Administration (NASA) operates a Boeing 747SP aircraft as an airborne astronomical observatory under the Stratospheric Observatory for Infrared Astronomy (SOFIA) Program. This aircraft N747NA S/N 21411 is operated by NASA Armstrong Flight Research Center (AFRC) and is located at Palmdale, CA.

The SOFIA aircraft is a Boeing 747SP. It was originally acquired by Pan American World Airways and was delivered in May 1977. In February 1986, United Airlines purchased the plane.

United removed it from active service in December 1995, and it was purchased by NASA in 1997. The aircraft was substantially modified for its new role as a flying astronomical observatory by L-3 Integrated Systems of Waco, Texas. To ensure proper modification, a dismantled section from another 747SP was used as a full-size mock-up.

The Stratospheric Observatory for Infrared Astronomy (SOFIA) consists of a specifically configured 2.5-meter diameter Telescope Assembly (TA) mounted inside the aircraft. The telescope observes space-based objects through a large articulating open port in the upper left-hand quadrant of the aircraft fuselage aft of the wing. A pressure bulkhead separates the un-pressurized telescope optics compartment from the forward passenger cabin; the telescope extends through this pressure barrier with the science instrument mounted in the pressurized passenger section, providing hands-on access to the investigators.

Type Aircraft Boeing 747SP-09 Tail Number N747NA

Line Number 306 Serial Number 21441 Total Hours 78,076 Total Cycles 10,576

Type Engine PW JT9D-7J

ENGINE POSITION SERIAL NUMBER

Engine POS 1 662413 Engine POS 2 686007 Engine POS 3 695767 Engine POS 4 662478

2.0 Objective and Scope

2.1 Engine #P662676 repair

Engine Serial Number P662676 has multiple items that require work. This includes:

1. Replacement of combustion liner due to a crack on the inner liner that is out of limits.

2. Welding of the R-flange at the 11:00 position

3. Welding along the S-flange at the clevis pinhole located on the inboard right side.

4. Replace engine fan case rub strips that are worn beyond limits.

5. Repair skin dent at exhaust plug

6. Provide, install and test fuel heater

7. Replace rivet on #2 inlet guide vane at the 3 O’clock position

8. Replace engine nozzle guide vane that has a crack located at the 6 O’Clock position

9. Replace oil line coming from gearbox going to fuel oil heat exchanger on outboard side of engine.

2.2 Engine #P686009 repair

Engine Serial Number P686009 has multiple items that require work. This includes:

1. Replace engine combustion liner due to cracks on the outer liner with US

Government supplied combustion liner

2. Replace damaged exhaust plug rivet

3. Perform fuel heater leak check

2.3 Contractor shall perform the following:

• Ship engine from Palmdale, California to contractor repair facility

• Provide a serviceable combustion liner

• Provide disassembly, assembly and labor required to replace the combustion liner and other components listed

• Perform a pre-induction test run per Pratt & Whitney JT9D, Engine

General, Acceptance Test

• Perform engine Borescope inspection In Accordance With (IAW) Boeing

AMM 747 72-00-00/601

• Perform Water Wash IAW P&W EM 72-00-00 Engine General Cleaning-

02 (Engine Gas path Cleaning)

• Perform AD 2009-04-18 Inspection Vane and Rotor Contact

• Perform “C” check inspection IAW Boeing AMM 71-00-02_601 SPARE ENGINE

“C” CHECK

• Perform engine TEST # 20 IAW Pratt and Whitney Engine Manual

• Review and update all engine documentation based on provided repairs by this SOW and submit to NASA

• Update all Time Since New (TSN), Cycles Since New (CSN), Time Since Repair

(TSR) records and submit to NASA

• Provide current status of Quick Engine Change (QEC) and accessories, include inventory and records and submit to NASA

• Review of repair records

• Last Test Cell report

• Engine Condition Monitoring (ECM) Report

• Aircraft and maintenance logs for reported discrepancies and repetitive inspection defects

• Prepare engine for shipment

• Ship engine from contractor repair facility to Palmdale, California

3.0 Work Requirements/Deliverables

• Provide NASA a detailed assessment for JT9D-7J SN P662676 engine.

• Life Limited Report including TSR, TSN and TSO of the engine module

• Provide a list of discrepancies found during the engine and Borescope inspections

• Provide a detailed engine documentation package which includes all repairs, overhaul and maintenance from OEM date or as available documentation allows.

• Provide detailed engine performance test report from Test #20.

• Provide a detailed summary of incorporated AD’s / SB’s and recommendations for the implementation of all outstanding AD’s / SB’s

• Provide a FAA 8130.

• Provide a detailed recommendation for assessed engine repairs for continued airworthiness

4.0 QUALITY ASSURANCE.

The Contractor shall provide and maintain a AS9100 certified Quality Management System. The Contractor’s inspection program shall ensure compliance with technical guidance, engineering specifications, and EASA/FAA regulations applicable to JT9D maintenance. Documentation shall be required for traceability, accountability, and a historical record of design, testing, inspection, qualification, and acceptance of all materials and components.

4.1 Quality System: The Contractor shall possess current FAA Repair Station certification to 14 C.F.R. Part 145 for engine maintenance. A certified repair station must establish and maintain a quality control system acceptable to the FAA that ensures the airworthiness of the articles on which the repair station or any of its contractors performs maintenance, preventative maintenance, or alterations.

4.2 Suppliers: The Contractor shall be responsible for Quality Assurance of vendors, suppliers, and subcontractors providing services under this contract to verify compliance with accepted standards. For those vendors who provide FAA certified parts and services, a copy of the valid certification shall be made available to NASA.

4.3 Non-conformance: The Contractor shall have in place a procedure for reporting of nonconforming articles, materials, and equipment. (“Non-conformance” is defined as a condition of any article, material, or service in which one or more characteristics do not conform to the specified requirements. This includes failures, discrepancies, deficiencies, defects, anomalies, and malfunctions).

4.4 Inspection: The Contractor shall provide inspectors to verify that work is performed in accordance with technical specifications and the documentation is completed in accordance with the Pratt and Whitney maintenance manual.

4.5 Tool Control: NASA requires the Contractor to utilize a system of positive tool control, including (but not limited to) shadowing of toolboxes. Contractors not in compliance with this requirement shall propose an alternative method of tool control.

5.0 CONTRACTOR QUALIFICATION REQUIREMENTS

The contractor shall certify (and/or provide evidence where required) that the following requirements are met, or where requested, propose an alternate approach.

5.1 STAFF EXPERIENCE . NASA requires that all technicians performing this maintenance are EASA/FAA Airframe or Power plant (A&P) certified for work on this engine type.

Technician assistants with proper oversight do not require this certification.

5.2 TOOLING. The Contractor shall certify that they possess or can obtain (prior to commencement of this effort) all fixtures, tooling, and support equipment necessary to perform the required engine maintenance. NASA will not provide any tooling or support equipment.

5.3 “ONE-STOP SHOP.” All work shall be performed at the same location. The engine shall not be moved to a subcontractor facility to complete the work or engine run.

5.4 REFERENCE MATERIALS. The Contractor shall possess all of the relevant JT9D technical reference material to perform this task except those provided by NASA.

5.5 SECURITY. The Contractor shall provide badged access restrictions to the facility that houses the engine to ensure that only authorized maintenance personnel have access to the engine.

5.6 Recognized as a Designated System Provider (DSP) for JT9D engine maintenance and overhaul services by Pratt & Whitney

5.7 Must be compliant with all PWGSP QA101 requirements

5.7.1 Coordinate with Pratt & Whitney’s JT9D Program Office on all aspects of operations, quality and compliance.

5.7.2 The contractor shall work closely with Pratt & Whitney Core Quality to ensure that the shop remains Audit Compliant, and there are regular quarterly meetings/reviews supporting these efforts.

6 .0 Other Requirements

6.1 Authorized Representative(s): NASA shall have the option to inspect the replacement Exhaust case prior to installation in the engine.

6.2 Test #20 oversight: NASA shall have the option to witness the Test #20 operation.

6.3 Warranties: The Contractor shall submit, and recover whenever possible, warranty claims for the Government for parts and labor. The Contractor shall maintain internal records of the warranty program, which shall be available for review by Government personnel. The Contractor shall pass through to the Government any supplier warranties acquired by the Contractor as a result of work performed under this contract.

7.0 Appendix

• Engine Life Limited Components (LLC) document