ENGINErunSOW_01292018.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. The aircraft is fitted with “J” powered engines in order to meet science mission requirements. These requirements often push the engine thrust capabilities to its maximum output.

Type Aircraft Boeing 747SP-09 Tail Number N747NA

Line Number 306 Serial Number 21441 Total Hours 78,560.1 Total Cycles 10,633

Type Engine PW JT9D-7J

2.0 Objective and Scope

2.1 In order to provide ready to install engines and to give the program as many spare engines as possible for support of the project for the 20-year life, the following engines need various levels of work detailed in this document to accomplish this goal.

2.2 Engines 662935, 689569(FE), 689573(FE), 662412, 662958, 685798, and 662514

2.3 All Engine Serial Numbers listed in Section 2.2 will require the following:

2.3.1 Untested Engine Test (Test 14) IAW 71-00-00_501

2.3.2 Trim Run

2.3.3 Vibration Run

2.3.4 Verify all AD and SB’s are up to date.

2.3.5 Preserve engine IAW AMM

2.3.6 See Section 2.2 for engine Serial numbers being tested, repaired or worked. Additional Engine specific requirements see Section

2.4 Contractor shall perform the following:

2.4.1 a pre-induction test run per Pratt & Whitney JT9D, Engine General, Acceptance Test.

2.4.2 engine Borescope inspection IAW Boeing AMM 747 72-00-00/601.

2.4.3 Water Wash in Accordance With (IAW) P&W EM 72-00-00 Engine

General Cleaning-02 (Engine Gas path Cleaning)

2.4.4 AD 2009-04-18 Inspection Vane and Rotor Contact.

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

“C” CHECK

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

2.4.7 Update all Time Since New (TSN), Cycles Since New (CSN), Time Since

Repair (TSR) records and submit to NASA.

2.4.8 Provide current status of QEC and accessories, include inventory and records and submit to NASA.

2.4.9 Provide review of repair records.

2.4.10 Provide review last Test Cell report.

2.4.11 Provide review Engine Condition Monitoring (ECM) Report.

2.4.12 Provide review aircraft and maintenance logs for reported discrepancies and repetitive inspection defects.

2.4.13 Prepare engine for shipment.

2.4.14 Ship engine from contractor repair facility to Palmdale, California.

2.5 Contractor shall perform the following engine specific work by Serial Number:

2.5.1 ENGINE 662514 REMOVED FROM SOFIA N747NA AIRCRAFT

POSITION # 3 (oil issue)

2.5.1.1 Crack on "R" flange at the 6:o'clock position. Needs Repair IAW

AMM 72-53-02

2.5.1.2 Robbed cannon plug assembly P/N MS24266R from the

generator disconnect, Replace cannon plug.

2.5.1.3 Hyd Hose Removed, Replace hoses IAW AMM

2.5.1.4 Removed Tandem bleed solenoid connector

2.5.1.5 Removed the Flow Divider

2.5.1.6 Removed pt4 TUBE pn-711985

2.5.1.7 Removed Bleed Valve

2.5.1.8 Removed Bleed Valve Solenoid

2.5.1.9 Fill Port Cap Broken

2.5.1.10 Engine run required to assess particles in oil chip detector issue

2.5.1.11 Engine Fan Case Rub Strips worn beyond limits

2.5.1.12 Inspect engine for missing components, document and

replace any missing components

2.5.2 ENGINE 662958 REMOVED FROM SCA-911

2.5.2.1 Verify Compliance of listed AD‘s

ESN 662958 had a shop visit in 2007, with no AD status report available. PAS was able to verify some of the AD’s due to work scope accomplished, however there is one that could not be verified. This is an external visual inspection of oil line clamping per AD 2003-24-12.

2.5.3 ENGINE 685798 REMOVED FROM SCA-911

2.5.3.1 Verify Compliance of listed AD

ESN 685798 from the records provided by PAS (Pulsar Aviation Services), indicates that there has not been a shop visit since 1990. With that being said there are several AD’s overdue as we are unable to find any supporting documents to show otherwise. Please review for compliance of all AD’s and submit cost to accomplish outstanding AD’s.

The biggest AD that is overdue is AD 96-25-10. The AD states that the Turbine Exhaust Case be removed and modified at next shop visit or 48 months, whichever occurs first? PAS has verified by PN that the case has been replaced and is willing to issue a work order to document this. This document was never issued.

2.5.4 ENGINE 689569 REMOVED FROM AIRCRAFT POSITION # 2

2.5.4.1 AD 93-19-02 500 Cycle Repetitive ECI

2.5.4.2 AD 99-15-02 PW SB 6343 CCOC “L” Flange – 689569 only

2.5.4.3 AD 2003-24-12 GB Pressure Tube and Front Pressure Manifold

P/N verification; inspection/modification

2.5.4.4 AD 99-20-09 Tangential Link Upper Bolt – 689569 only

2.5.4.5 AD 78-08-13 MGB Chip Detectors

2.5.4.6 Engine Fan Blades Root ECI

2.5.4.7 300-hour oil sample

2.5.4.8 AD 2000-23-14 No 4 Bearing Internal Oil Pressure Tube – AD compliance due at each disassembly of TEC

2.5.4.9 2009-04-18 Stg 2 HPT Rotor and Stator Assy borescope

(“leanback check”) – OE dispo states “No history of this AD being complied with. Comply with AD terminating action by completing SB 6488. Continue inspections on 1000 cycle intervals”;

inspection normally carried out at 2A check

2.5.4.10 SB 6502 ENGINE - COMBUSTION CHAMBER

ASSEMBLY - PROVIDE A COMBUSTION CHAMBER

ASSEMBLY THAT HAS HEAT SHIELDS MADE FROM A NICKEL

MATERIAL – Outer combustion chamber mod, no compliance time given. Do at shop visit

2.5.5 ENGINE 689573 REMOVED FROM AIRCRAFT POSITION # 1

2.5.5.1 AD 93-19-02 500 Cycle Repetitive ECI

2.5.5.2 AD 2003-24-12 GB Pressure Tube and Front Pressure Manifold

P/N verification; inspection/modification

2.5.5.3 AD 78-08-13 MGB Chip Detectors

2.5.5.4 AD 76-24-03 VI of Fan Blades

2.5.5.5 Engine Fan Blades Root ECI

2.5.5.6 300-hour oil sample

2.5.5.7 AD 2000-23-14 No 4 Bearing Internal Oil Pressure Tube – AD compliance due at each disassembly of TEC

2.5.5.8 2009-04-18 Stg 2 HPT Rotor and Stator Assy borescope

(“leanback check”) – OE dispo states “No history of this AD being complied with. Comply with AD terminating action by completing

SB 6488. Continue inspections on 1000 cycle intervals”;

inspection normally carried out at 2A check

2.5.5.9 SB 6502 ENGINE - COMBUSTION CHAMBER ASSEMBLY -

PROVIDE A COMBUSTION CHAMBER ASSEMBLY THAT HAS

HEAT SHIELDS MADE FROM A NICKEL MATERIAL – Outer combustion chamber mod, no compliance time given. Do at shop visit

3.0 Deliverables

3.1 Provide NASA a detailed assessment for JT9D-7J for each engine.

3.2 Provide quote to repair discrepancies found. Quotes should list labor rate and parts and material cost

3.3 Life Limited Report including TSR, TSN and TSO of the engine module, report in

Excel format

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

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

3.6 Provide detailed engine performance test report from all tests conducted.

3.7 Provide a detailed summary of incorporated AD’s / SB’s in Excel format and recommendations for the implementation of all outstanding AD’s / SB’s

3.8 Provide a FAA 8130.

3.9 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 with the following rating: Powerplant. 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 Must be compliant with all PWGSP QA101 requirements

5.6.1 Pratt & Whitney has a JT9D Program Office that is responsible for coordination on all aspects of operations, quality and compliance at these facilities.

5.6.2 The contractor works 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

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

6.1.2 Engine Test oversight: NASA shall have the option to witness any engine test operation.

6.1.3 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

7.1 Engine Life Limited Components (LLC) document

Type Aircraft Boeing 747SP-09