PWS Module 13-15 Navy 5 Mar 2012

PERFORMANCE WORK STATEMENT (PWS)

for the F108-200 Turbine Assembly-Low Pressure Union Assemblies

MODULE #13/15

PURCHASE REQUEST NUMBER: FD2030-11-35995

REV. 0

PREPARATION DATE: 5 Mar 2012

PREPARING ORGANIZATION:

Navy E6 ISS Tinker Propulsion Engineering Code 4.4.3.3

TINKER AFB, OK 73145-3031

TABLE OF CONTENTS

Page

TABLE OF CONTENTS

SECTION 1

1.0

DESCRIPTION OF SERVICES

1.1 Receiving

1.2 Disassembly 1.3 Remanufacture

1.3.1 Remanufacture Procedures

1.3.2 Remanufacture Deviations

1.3.3 Designated Engineering Representative (DER) Processes and Procedures 1.3.4 Parts Not Listed in the Illustrated Parts Catalog (IPC)

1.3.5 Condemnation of Tracked Items

1.3.6 Special Instructions Concerning the Navy CFM56-2A Modules

1.4 Re-installation of Life Limited Components

1.5 Federal Aviation Administration (FAA) Form 8130-3

1.6 Quality System and Quality Assurance 1.7 Deficiency Report (DR) Investigation 1.8 Condemned Assets 1.9 Packaging and Handling 1.10 Reporting 1.11 Shipping and Transportation 1.12 Document Storage 1.13 Mission Essential Services

SECTION II

2.0

SERVICE SUMMARY (SS)

2.1 Service Summary Requirements 2.1.1 Performance Objective(s)/Threshold(s)

2.1.2 Surveillance Methods 2.2 F108 Module 13/15 Services Summary 2.3 Contractor Performance Evaluation

SECTION III

3.0

GOVERNMENT PROPERTY

3.1 Government Furnished Material (GFM) 3.2 Government Furnished Property (GRP)

APPENDIX “A”

ACRONYMS

ENCLOSURE 1

4.0

STATEMENT OF WORK

SECTION 1

1.0

DESCRIPTION OF SERVICES

The purpose of this PWS is to define the remanufacturing requirements for the F108-200 (CFM56-2A) Low Pressure Rotor and Frame Assembly that applies to the following National Stock Numbers (NSN) and Part Numbers (P/N):

LOW PRESSURE ROTOR AND FRAME ASSEMBLY MODULE #13/15

F108-200 (CFM56-2A)

Input P/N Output P/N

Input NSN

Output NSN____

305-482-302-0-2A 305-482-302-0-2A 2840-01-484-3913PN 2840-01-484-3913PN

The instructions stipulated are brief, concise statements providing general requirements for remanufacturing of the F108 Module 13/15which have approximately 15,000 to 23,000 Engine Operating Hours. The contractor shall maintain a Federal Aviation Administration Part 145 rated repair facility rated to remanufacture CFM56-2A engine components; contractor must have the remanufacture capabilities to include appropriate technical data, repair documents, and license agreements, required to accomplish remanufacture of F108 Module 13/15. The contractor is responsible for the production, remanufacture and scheduled delivery of a quality product.

1.1 Receiving: The contractor shall perform a visual inspection upon receipt for any shipping or packaging damage. Module 13/15 assemblies received which are misidentified, misdirected, incomplete or have missing parts shall be reported to the Procurement Contracting Officer (PCO) in writing, email is acceptable, for disposition instructions.

1.2 Disassembly: The contractor shall completely disassemble, each Module 13/15 in order to remanufacture or replace the Module 13/15 component parts. Complete disassembly is required to comply with Engine Shop Manual (ESM) inspection requirements and CFM-56-2A Service Bulletins listed in this PWS.

1.3 Remanufacture: The contractor shall remanufacture the Module 13/15 as follows:

1.3.1 Remanufacture Procedures: Low Pressure Turbine Rotor and Frame Union of Assemblies and component parts shall be remanufactured IAW the procedures outlined in the CFM56-2A ESM 72-54-00 through 72-54-20 and 72-56-00 through 72-56-10. Component parts removed from rotor and frame assembly shall be inspected to piece part requirements outlined for that specific part in accordance with CFM56-2A ESM. As a minimum, the latest revision of the CFM56-2A service bulletins listed in paragraph 1.3.6.1 are to be incorporated if not previously complied with along with any outstanding FAA Airworthiness Directives.

1.3.1.1 Level of Inspection: Component parts removed from rotor and frame assembly shall be inspected to piece part requirements outlined for that specific part in accordance with CFM56-2A ESM.

1.3.1.2 Air Seals: Repair 001, LPT rotating air seals (72-54-06), Repair 001, LPT Inner stationary air seals (72-54-09) and Repair 001, LPT outer stationary air seals (72-54-12) are to be accomplished 100% to restore seals the unworn condition.

1.3.1.3 LPT Blades: LPT stage 1 thru 4 blades will be inspected and reworked as necessary. Blades beyond repair limits shall be replaced with new blades from OEM approved sources or fully overhauled blades from other Navy assets. Used Commercial Stock shall not be used for LPT blade replacement.

1.3.1.3.1 All LPT blades used must meet the following pre-twist angle requirements:

Stage 1 minimum pre-twist angle = 1.82 deg

Stage 2 minimum pre-twist angle = 2.55 deg

Stage 3 minimum pre-twist angle = 3.50 deg

Stage 4 minimum pre-twist angle = 4.70 deg

1.3.1.4 Module Inspection: In addition to the component piece part inspections all Modules returned to service shall meet the inspection criteria established in T.O. Reference CFM56-2A Engine Shop Manual Task 72-00-54-200-001-D “Low Pressure Turbine Rotor/Stator Module-Inspection” with special attention to inspections that address possibility of LPT blade unlatches.

1.3.1.5 Adjusting Sleeve Considerations: The Turbine Frame Assembly is matched with the Low Pressure Turbine Rotor Assembly through #5 bearing adjusting sleeve. The replacement of Turbine Frame or of the No. 5 bearing support cannot be done without rework of the adjusting sleeve per CFM56-2A, ESM 72-00-03 (Refer to caution in 72-00-56-20 turbine frame removal) after removal and disassembly of the Module. During removal the parts must be identified and match-marked for inspection and installation operations.

1.3.1.6 HPT Rear Turbine Frame Cleaning and NDI Inspection: CFM56-2A Program has a history of Rear Turbine Frame cracks. To address this issue perform NDI inspection of Rear Turbine Frame IAW SOW E6-PN-318A-10 found in Enclosure 1. Equivalent contractor cleaning process is acceptable.

1.3.2 Remanufacture Deviations: Prior to contractor’s use in remanufacturing of Module 13/15 or component parts, the contractor shall obtain written approval from the PCO for any deviations from the processes, materials, material processes or procedures outlined in CFM56-2A ESM 72-54-00 thru 72-54-20 and 72-56-00 thru 72-56-10, or Service Bulletin authorized modifications.

1.3.3 Designated Engineering Representative (DER) Processes and Procedures: Prior to contractor’s use in remanufacturing of Module 13/15 or component parts, the contractor shall obtain written approval from the PCO for all DER processes and procedures.

1.3.4 Parts Not Listed in the IPC: Use and/or reuse of any part not listed specifically in the CFM56-2A Illustrated Parts Catalogue (IPC) shall be identified to the PCO and must be authorized by Navy Propulsion Engineering for the CFM56-2A.

1.3.5 Condemnation of Tracked Items: Condemned Tracked Parts/ Components not meeting Build Policy do not require disposition from Navy Propulsion Engineer.

1.3.6 Special Instructions Concerning the Navy CFM56-2A Modules: In the following are special instructions concerning the CFM56-2A modules.

1.3.6.1 Service Bulletins: As a minimum comply with the following CFM56-2A Service Bulletins (SB) and record compliance on the FAA Form 8130.3 that accompanies the assets back to supply.

· SB 72-338: Reidentification of Low Pressure Turbine (LPT) Conical supports and LPT Stub shafts (Air Directive 96-18-16)

· SB 72-356: Anti-Rotation lock replacement rework/reidentification of Stage 2 and 3 Stationary Air Seal Segments

· SB 72-372: Reidentification of Conical Supports

· SB 72-144: Increase in height of the Abradable Honeycomb on Stage 1 Outer Stationary Air Seal

· SB 72-541: Turbine Frame (72-56-00) - Rework of the Old LPT Frame Assy to permit the removal of the Oil Supply Tube Elbow Assy on wing

1.3.6.2 Reidentify the remanufactured/reconditioned Module 13/15 assembly by adding “-2A” to the assembly Part Number to read 305-482-302-0-2A. Permanently mark assembly using a CFM International authorized method or equivalent with a “-2A” after the assembly part number in the location allowed by the blueprint.

1.3.6.3 The CFM56-2A assets will be shipped with a statement on the FAA 8130-3 form required in paragraph 1.5 that states that the Source of Repair (SOR) complied or did not comply with the service bulletins of this paragraph. It is understood that some service bulletins may not apply. If a service bulletin was not applicable, this is to be stated on the serviceable tag or FAA document.

1.3.6.4 The offeror shall use non-life limited Navy CFM56-2A assets unless repairs cannot be accomplished in a 30 day time frame. If the work requires more than 30 days, the offeror shall inform the PCO and request a stated additional amount of time to complete the work. If the Navy assets are then condemned and commercial assets are the only avenue to provide serviceable assets, there will be a limit of one repair cycle on any component accepted by the Navy. (This paragraph does not apply to LPT Blades of paragraph 1.3.1.3.)

1.4 Re-installation of Life Limited Components: Time tracked/life limited components that were removed for a required inspection shall be assembled into same rotor. Check records to ensure specified life cycles have not been exceeded and part must have at least 5100 cycles (Build Policy) remaining to max life limit for the CFM56-2A components. When a component part exceeds max life cycle limit or has insufficient life cycles remaining, the replacement part selected for that rotor shall have equal or greater life cycles remaining than all other component parts in that rotor assembly.

Life limited/time tracked parts removed from a Navy F108-200/CFM56-2A assembly will not be replaced with a component/part that has operated in any configuration other than a Navy F108-200/CFM56-2A engine. Serialized parts will not be co-mingled with or replaced by repaired/reconditioned commercial parts from any other sources or fleets.

1.5 FAA Form 8130-3: SOR shall provide a completed FAA Form 8130-3, Airworthiness Approval Tag, with each assembly or component part that has been Reworked/Remanufactured with the intent of approval for returning these assemblies or components parts to service. In item 13 (remarks), list CFM56-2A the Service Bulletins complied with to rework/modify part or assembly to authorized output part number. (Example: CFM56-2A, SB 72-338 complied with or CFM56-2A, SB 72-338 not required).

1.6 Quality System and Quality Assurance: Each Module 13/15 identified as serviceable shall be delivered to the Government defect free. The contractor shall develop and maintain a system that adheres to the requirements of International Standard Organization (ISO) 9001.2000/ANSI/ASQC Q92, Quality Systems Model for Quality Assurance in Design/Development, Production, Installation, and Servicing and supplement requirements imposed by this contract. Develop and implement procedures to properly maintain measuring and test equipment in accordance with ANSI/NCSL 2340-1. The quality system will include a clear and complete set of work documents for all maintenance required by this contract. The quality program shall be designed to promptly detect and correct conditions adverse to quality.

1.7 Deficiency Report (DR) Investigation: At the Government’s request, the contractor shall investigate and submit findings to include root causes and a corrective action against all DRs submitted to contractor against items remanufactured by this contract which are reported to be defective.

1.8 Condemned Assets: Module 13/15 component parts that do not meet present and inspection limits, shall be condemned at the contractor’s facility and processed through Plant Clearance Automated Reutilization Screening System (PCARSS). Provide government quantities by P/N and NSN of reparable components condemned and annotate on 413 Monthly Production Report CDRL DD Form 1423.

1.8.1 Condemned Asset Reporting: Condemned Module 13/15 component parts shall be reported via CDRLs Form 413, Monthly Production Report and Commercial Asset Visibility for Air Force (CAVAF) System. Condemnations shall be reported to 421 SCMS/GUMBA, Air Force Global Logistics Support Center (AFGLSC) services to establish usage rates and cost planning.

1.9 Packaging and Handling: The Module 13/15 shall be properly packaged in accordance with Air Force Materiel Command (AFMC) Form 158 Packaging requirements. A serviceable tag, Department of Defense (DD) Form 1574, shall be placed inside the package along with the assembly and another DD Form 1574 shall be attached to the outside of the package. In addition, all marking and labeling of unit and shipping containers shall be in accordance with MIL-STD-129P, Department of Defense Standard Practice, Military Marking for Shipment and Storage.

1.10 Reporting: The contractor shall meet the delivery schedule. The contractor shall provide completed Certificate of Conformance documentation with each Module 13/15 and its component parts that have been remanufactured with the intent of returning these assemblies or component parts to service. This documentation shall have part number, serial number, work accomplished, Service Bulletins complied with, on serviceable tag, DD Form 1574. The contractor shall ensure that all reporting as specified under the following Contract Data Requirements is accomplished:

A001: Commercial Asset Visibility Air Force (CAVAF) Reporting, formerly CAVII A002: AFMC Form 413 (Depot Maintenance Production Report)

A003: Comprehensive Engine Management System (CEMS) Reporting

A001:

CAVAF Reporting - The contractor shall input the data IAW the Appendix B and CAVAF guide.

A002:

AFMC 413 Monthly Reporting - Data in accordance with the AFMC Form 413 report shall not be waived, although contractor’s format with all the same data elements as the AFMC Form 413 report may be accepted, if approved through the PCO.

A003:

CEMS Reporting - Each Serial Number Module 13/15 assembly is loaded into Comprehensive Engine Management System (CEMS) system and all part number changes must have documentation accomplished.

The point of contact for verification of part numbers and serial numbers for the Navy NSN: 2840-01-484-3913PN (CII: HG108E0/HG108G0) is Steven Gastineau, Equipment Specialist (405) 736-5941, OC-ALC/ GKGBAA email: steven.gastineau@tinker.af.mil.

In addition, the contractor shall submit Supply Discrepancy Reports (SDRs) when required IAW the contract’s Appendix B, “End Item and Government Furnished Equipment Management,” Section 7. Contractor shall process Deficiency Reports when required IAW Section 1.4 of this PWS.

1.11 Shipping and Transportation: The contractor shall meet the delivery schedule as outlined in Schedule B of the contract. The Contractor shall ship or transport applicable assets as appropriate in order to have the assets available to support the customer’s operational requirements and IAW the contract. The Contractor shall not destroy reusable shipping containers, and will reuse them for return shipment.

1.12 Document Storage: All records and reports outlined in this PWS shall be prepared for each part and a copy kept on file by the Contractor for five (5) years. The Government Technical Representative reserves the right to request and view any records at any time.

1.13 Mission Essential Services: N/A "CONTRACTOR EMPLOYEES: Contractor employees shall identify themselves as Contractor personnel by introducing themselves or being introduced as Contractor personnel and displaying distinguishing badges or other visible identification for meetings with Government personnel. In addition, contractor personnel shall appropriately identify themselves as contractor employees in telephone conversations and in formal and informal written correspondence".

SECTION II

2.0 Service Summary (SS): Contractor performance shall be measured and assessed, using the Performance Objectives listed in the Module 13/15 SS, Table 2-1.

The contractor service requirements are summarized into performance objectives that relate directly to the mission essential items. The performance threshold describes the minimum acceptable levels of service for each requirement. The contractor shall be aware that the absence of any contract requirement from the SS does not detract from its enforceability nor limit the rights or remedies of the Government under any other provision of the contract. The Contractor shall ensure the following service summary requirements are accomplished:

2.1 Service Summary Requirements: The contractor shall ensure the performance objectives and performance thresholds identified in Table 2-1 of this PWS is achieved as follows:

2.1.1 Performance Objectives and Thresholds: The Contractor shall achieve performance thresholds identified in Table 2-1 of this PWS. The contractor service requirements are summarized into performance objectives that relate directly to the mission essential items. The performance threshold describes the minimum acceptable levels of service for each requirement. The government will use the surveillance methods contained in the performance plan to evaluate the contractor’s performance for the performance objectives listed below. In the event the performance objective is not met, the contractor will be given a reasonable time after notification to correct the unacceptable performance, if such correction is possible. The contractor shall immediately take corrective action in accordance with the performance threshold(s). In cases where the contractor fails to implement corrective action, the PCO will take appropriate measures.

NOTE:

The F108 Module 13/15 Government Production Management Specialist (PMS) and PCO will exercise surveillance over the performance thresholds. The absence of any contract requirement from the SS shall not detract from this enforceability nor limit the rights or remedies of the Government under any other provision of the contract.

2.1.2 Surveillance Methods: The Contractor shall support the PMS and PCO surveillance methods as identified below:

a. Periodic Inspection of Process or Output

b. Random Sampling of Recurring Service Output

c. 100 Percent Inspection of Output

d. Customer Observation or Complaint

NOTE 1: The method of surveillance may include one or more of the methods specified above.

NOTE 2: The Government will use the methods contained in the Performance Plan (PP) to evaluate the Contractor’s performance for the listed performance objectives. The Module 13/15 Government PMS and/or PCO will monitor contractor performance to determine if it meets the contract thresholds as set forth in the performance measures and this PWS.

2.2 F108 Module 13/15 Service Summary:

Table 2-1

Performance Objective

Threshold

SS - 1

Quality Product:

Each of the F108 Module 13/15

Identified as serviceable shall be delivered to the Government defect free.

IAW PWS Para 1.6

100% of F108 Module 13/15 Delivered shall be defect free.

The contractor shall meet the delivery schedule.

2.3 Contractor Performance Evaluation: The contractor shall be aware that the evaluation of performance will occur when the PMS evaluates the service of the Contractor to determine whether or not it meets the performance measures of the contract.

SS -1:

The contractor's failure to meet this requirement shall result in a negative CPAR rating and remedies as allowed under FAR 52.212-4 Inspection/Acceptance.

SS - 2:

The contractor's failure to meet this requirement shall result in a negative CPAR rating and remedies as allowed under FAR 52.212-4 Inspection/Acceptance.

SECTION III

3.0

GOVERNMENT PROPERTY

3.1 Government Furnished Material (GFM): None. Contractor shall furnish all material, support equipment, tools, test equipment and services. Government Furnished Material will not be provided. Contractor furnished material used for replacement shall be parts specified in ESM CFM56-2A Engine Shop Manual or have written approval from Navy Propulsion Engineering, OC-ALC/GKGBAA and OCALC/GKGBAB in writing through the PCO. No commercially used or overhauled material can be used in the repair of these modules.

3.2 Government Furnished Property (GFP): All parts to be remanufactured will be shipped to the contractor.

NOTE: For those requirements listed in Section II, Service Summary, the Performance Plan will follow the methods of surveillance specified in the Performance Plan. The Performance Plan is authorization for the Governments PCO to participate in the administration of this contract.

APPENDIX “A”

ACRONYMS

ACSS

Air Combat Sustainment Squadron

AF

Air Force

AFMC

Air Force Materiel Command

CAVAF

Commercial Asset Visibility Air Force

CEMS

Comprehensive Engine Management System

CDRL

Contract Data Requirements List

CFMI

CFM International

CII

Configured Item Identifier

CMM

Commercial Maintenance Manual

DD

Department of Defense

DER

Designated Engineering Representative

DCMA

Defense Contract Management Agency

DR

Deficiency Report

ESM

Engine Shop Manual

FAA

Federal Aviation Administration

FAR

Federal Acquisition Regulation

IAW

In Accordance With

ISO

International Standards Organization

LPT

Low Pressure Turbine

NSN

National Stock Number

OC-ALC

Oklahoma City Air Logistics Center

PCO

Procurement Contracting Officer

PCARSS

Plant Clearance Automated Reutilization Screening System

P/N

Part Number

PMS

Production Management Specialist

PP

Performance Plan

PWS

Performance Work Statement

SB

Service Bulletin

SDR

Supply Discrepancy Report

S/N

Serial Number

SRAN

Stock Record Account Number

SS

Service Summary

SOW

Statement of Work

TAFB

Tinker Air Force Base

USAF

United States Air Force Enclosure 1

4.0

STATEMENT OF WORK

SOW Number: E6-PN-318A-10

Date: 23 Apr 10

Subject: HPT Rear Turbine Frame Cleaning and NDI Inspection

WUC: 27631F0

References:

A) CFM Engine Shop Manual

B) 79-007 76PMXG Cleaning/Blasting Process

C) 97-003 76PMXG NDI Process Order

D) 2J-F108-2-2-70-21-41

E) 2J-F108-2-2, Task 70-32-21-230-10

Cancellation: None

Background

1. This Rear Turbine Frame (RTF) NDI is required because the Navy CFM56-2A fleet has found 3 cracked RTFs with cracked struts and circumferential case cracks. This cleaning and inspection process at OC/ALC was prototyped with Navy Propulsion Engineer, OC/ALC Planner and OC/ALC Chemical Cleaning Process Engineer involved in the effort.

2. This is SOW is written assuming the 13/15 Module will be removed from the engine and the front engine assembly shop will send the RTF out for inspection. This process will be accomplished to all Navy engines when module 13/15 is removed for engine repair.

Detailed Instructions

1. Remove RTF/Sump Assembly from LPT Rotor Assembly (Module 13) IAW CFM56-2A Engine shop Manual (ESM).

2. Remove the #5 Bearing, # 5 Bearing Support, Forward Sump Assembly, the Fairing from the Struts, and the asbestos lined tube brackets IAW CFM56-2A Engine shop Manual (ESM). Hold these parts to install on frame upon return from inspection.

3. Clean RTF/Sump Assembly IAW F108-2-2-70-21-41 (Process A).

4. Pressure Wash (HCP1) RTF/Sump Assembly and insure all tubes are rinsed out.

5. Manually flush all tubes and cavities.

6. Bake part at 2750 F to remove moisture from internal cavities.

7. Prepare part for NDI inspection. Cover Sump cavity and tubes with plastic prior to NDI to prevent as much NDI Penetrant as possible from getting into internal cavities and passages.

8. FPI RTF IAW 2J-F108-2-2 Task 70-32-21-230-10 (Level 2 Sensitivity). Although all of turbine frame is to be inspected (except surfaces internal to the Sump), areas of most interest are the Struts near the weld seams and the outer case with in approximately 1/2 inch AFT of the FWD Flange. No cracks are allowed.

9. Pressure Wash (HCP1) RTF Assembly and insure all tubes are rinsed out.

10. Bake part at 275°F to remove moisture from internal cavities.

File No: FD2030-11-35995

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File No: FD2030-11-35995