SOWModule1315Navy1Mar17.pdf

File No: FD2030-15-02631

STATEMENT OF WORK (SOW)

F108-200 Low Pressure Turbine Union of Assemblies

MODULE #13/15 (Navy)

PURCHASE REQUEST NUMBER: FD2030-15-02631

REV. 0

PREPARATION DATE: 1 March 2017

PREPARING ORGANIZATION:

Navy E-6B ISSC Propulsion Engineering Team

Technical Element (Navy Code 4.4.3.3)

TINKER AFB, OK 73145-3031

TABLE OF CONTENTS Page

TABLE OF CONTENTS 1

SECTION 1

1.0 SCOPE 2

1.1 Introduction 2

1.2 Receiving 2

1.3 Disassembly 2

1.4 Remanufacture 2

1.4.1 Remanufacture Procedures 2

1.4.2 Remanufacture Deviations 3

1.4.3 Designated Engineering Representative (DER) Processes and Procedures 3

1.4.4 Parts Not Listed in the Illustrated Parts Catalog (IPC) 4

1.4.5 Condemnation of Tracked Items 5

1.4.6 Special Instructions Concerning the Navy CFM56-2A Modules 5

1.5 Re-installation of Life Limited Components 5

1.6 Federal Aviation Administration (FAA) Form 8130-3 5

1.7 Quality System and Quality Assurance 5

1.8 Deficiency Report (DR) Investigation 5

1.9 Condemned Assets 6

1.9.1 Condemned Asset Reporting 6

1.10 N/A 6

1.11 Packaging and Handling 6

1.12 Reporting 6

1.13 Contractor Manpower Reporting 7

1.14 Shipping and Transportation 8

1.15 Document Storage 8

1.16 Preservation 8

1.17 Shipping and Transportation 8

1.18 Contractor Identification to Government Employees 8

1.19 Safety 8

1.20 Mission Essential Services 8

SECTION II

2.0 GOVERNMENT PROPERTY 9

2.1 Government Furnished Material (GFM) 9

2.2 Government Furnished Property (GRP) 9

APPENDIX “A”

ACRONYMS 9

ENCLOSURE 1

3.0 STATEMENT OF WORK 10

SECTION 1

1.0 SCOPE

1.1 Introduction: The purpose of this SOW 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 Number (NSN): 2840-01-484-3913PN and Part Number (P/N): 305-482-302-0-2A

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 remanufacture facility 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.

1.2 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 and incomplete or have missing parts shall be reported to the Procurement Contracting Officer (PCO) in writing, email is acceptable, for disposition instructions.

The contractor shall report in accordance with CDRL A005 any F108 Module 13/15 Navy that are misidentified, misdirected, incomplete or missing parts to the PCO in writing (email is acceptable) for disposition instructions. In addition the Contractor shall examine shipments for any packaging damage.

The contractor shall not destroy reusable shipping containers and will reuse them for return shipment.

The contractor shall submit a Supply Discrepancy Report (SDRs) IAW Contractor Data Requirements List (CDRL) A005 (SOW Para 1.7 Reporting) for such shipments as described above via the Department of Defense (DoD) web-based application WebSDR, located at:

https://www.transactionservices.dla.mil/daashome/websdr.asp.

This system of reporting an SDR has been developed in compliance with DoD Management (DoDM) regulation 4140.1-V1, and Defense Logistics Management (DLM) regulation 4000.25-M, Supply Standards and Procedures, which requires automated SDR processing and IAW Contractor Asset Visibility for the Air Force (CAV AF) Statement of Work (SOW). The prime packaging specialist may authorize exceptions to these requirements.

1.3 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 SOW.

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

1.4.1 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 1.4.6.1 is to be incorporated if not previously complied with along with any outstanding FAA Airworthiness Directives.

https://www.transactionservices.dla.mil/daashome/websdr.asp

1.4.1.1 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.

1.4.1.2 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 to an unworn condition.

1.4.1.3 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.

Used Commercial Stock shall not be used for LPT blade replacement.

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

Stage 1 min = 1.82 deg; max = 2.32 deg Stage 2 min = 2.55 deg; max = 3.05 deg Stage 3 min = 3.50 deg; max = 4.00 deg Stage 4 min = 4.70 deg; max = 5.20 deg

1.4.1.4 Module Inspection: In addition to the component piece part inspections identified in CFM56-2A 72-54, 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” specifically with respect to:

1) Circumferential looseness of blades at tip-shrouds.

2) Pre-twist gaps such that adjacent interlocks do not touch

3) Shingled or unlatched blade tip-shrouds

1.4.1.5 No. 5 Bearing Adjusting Sleeve Considerations:

The Turbine Frame Assembly is matched with the Low Pressure Turbine Rotor/Stator Assembly by way of concentricity of the #5 bearing adjusting sleeve with respect to the LPT case forward flange. Replacement of Turbine Frame or of the No. 5 bearing support will require replacement of the adjusting sleeve per CFM56-2A, ESM 72-00-03 (Refer to caution in 72-00-56-20 turbine frame removal). Upon completion of all refurbishments/ rework and after modules 13 and 15 have been reassembled and joined as a “union of assemblies”, the #5 bearing sleeve must be checked for said concentricity either as part of the bearing-sleeve preplacement process or – if there was no initial requirement to replace the sleeve – as a final inspection. If the measured concentricity exceeds 0.002 inch then the bearing sleeve will have to be replaced and undergo match-grind to meet concentricity requirements.

1.4.1.6 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.

1.4.2 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.

1.4.3 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.

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

1.4.5 Condemnation of Tracked Items: Tracked Parts/Components that have a remaining life of less than 5100 Maj Cycles (Navy Build Policy – ref. paragraph 1.5) require disposition from Navy Propulsion Engineer. The Navy may elect to use components that are within a few hundred cycles of meeting the Build Policy requirements. In such instances Navy will provide written authorization to use the affected item.

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

1.4.6.1 Service Bulletins: As a minimum offeror shall comply with the latest version of the following CFM56-2A Service Bulletins (SB). SB compliance shall be recorded on DD Form 1574 (Serviceable Tag-Materiel) and on FAA Form 8130.3 that accompany the assets back to supply.

o SB 72-338: Re-identification of Low Pressure Turbine (LPT) Conical supports and LPT Stub shafts (Air Directive 96-18-16) o SB 72-356: Anti-Rotation lock replacement rework/reidentification of Stage 2 and 3 Stationary

Air Seal Segments o SB 72-372: Reidentification of Conical Supports o SB 72-144: Increase in height of the Abradable Honeycomb on Stage 1 Outer Stationary Air

Seal o 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 o SB 72-602: Replacement of Suspect Stage 1 LPT Blades 301-330-114-0 and 301-330-115-0

NOTE: The CFM56-2A Navy Fleet Service Bulletin 72-602 applies only to three (3) 13/15 Modules. These engines are not scheduled in but FOD or other engine issues could drive them in.

Applicable engine and module S/N follow: Engine S/N 783196 Module S/N 0054XL3789, Engine S/N 783206 Module S/N 0054XL7539, and Engine S/N 783250 Module S/N 0054XL7576.

1.4.6.2 Re-identify 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.

1.4.6.3 The CFM56-2A assets will be shipped with a statement on the FAA 8130-3 form required in paragraph 1.6 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.

1.4.6.4 When a non-life-limited component must be condemned/replaced or when it is repairable, and cannot be made serviceable within a 30 day time frame, the offeror may use, as a replacement, a serviceable commercial asset – either of the same part number, or of an associated newer configuration part number (identified in the CFM 56-2A IPC) - provided that it has not undergone more than one repair cycle. (This paragraph does not apply to LPT Blades; See paragraph 1.4.1.3)

1.4.6.5 Special Measurements: Measure and record the following module 13 features on DD Form 1574 (Serviceable Tag-Materiel) and on the FAA Form 8130.3 that accompany the assets back to supply:

1) LPT Case diameter D: 34.476-34.484(serviceable) or 34.4803-34.4838(repaired)

2) LPT 1st Stage Shroud Support (un-installed) diameter B: 34.653-34.665(serviceable) or 34.6614-34.665(repaired) and diameter C: 34.468-34.480(serviceable) No repair.

3) LPT 1st Stage Shroud Support diameter B while installed on the LPT case.

1.5 Re-installation of Life Limited Components: Tracked/life-limited components that meet the minimum remaining life requirement and are serviceable subsequent to inspection/ remanufacturing shall be utilized in the same rotor as that from which they were removed. Before processing life-limited components, check records to ensure that they have at least 5100 major cycles remaining (IAW established Build Policy).

Tracked/ life-limited parts shall not be replaced with parts that have operated in any configuration other than a Navy F108-200/CFM56-2A engine.

1.6 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).

1.7 Quality System and Quality Assurance: Each of the F108 Module 13/15 Navy identified as serviceable shall be delivered to the Government defect free. The Contractor shall ensure that materials, parts, and accessories used in overhauled components are restored to original life expectancy or nearly so, and are interchangeable without alteration. 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.

1.8 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 deficiency reports submitted to Contractor for items remanufactured by this contract which are reported to be defective. Each DR will be processed IAW Technical Order (T.O.) 00-35D-54, USAF Material Deficiency Reporting System, in a timely manner to meet suspense dates assigned by the action agency. Reference CDRL A004.

1.9 Condemned Assets: Condemnation of Module 13/15 components that are classified as high-cost (all life limited components plus the turbine frame and turbine case) that do not meet serviceable inspection and/or repairable limits, shall be coordinated with Navy engineering prior to actual dispositioning. All high-cost components that receive approval for condemnation from Navy engineering along with all other (lower-cost) components that are assessed to be unserviceable and/or not-repairable, shall be condemned at the contractor’s facility and processed through Plant Clearance Automated Reutilization Screening System (PCARSS). Provide government quantities by P/N, NSN and S/N of repairable components condemned and annotate on Contract Depot Maintenance (CDM) Production Report CDRL DD Form 1423.

1.9.1 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.

1.10 N/A:

1.11 Packaging and Handling: The contractor shall be responsible for the preservation and packaging of the F108 Module 13/15 IAW the Special Packaging Instructions specified on AFMC Form 158. The contractor shall place a serviceable tag, Department of Defense (DD) Form 1574, inside the package along with the assembly as well as outside the package.

In addition, all marking and labeling of unit and shipping containers shall be in accordance with Mil-Std-129R, Department of Defense Standard Practice, Military Marking for Shipment and Storage. Use additional guidance for preparation and shipment IAW T.O. 00-20-1, 00-20-3, MIL-STD-2073-1, MIL-STD-129, AFPAM24-237, and AFMAN 24-206. This contract does not allow for Commercial Packaging

1.12 Reporting: The contractor shall meet the delivery schedule. The contractor shall provide completed FAA Form 8130-3 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. Block 13 (Remarks) of FAA Form 8130-3 shall contain the statement:

In addition to compliance with the regulations identified in blocks 14 and 19; it is hereby certified that all the imbedded items comply with the stipulations of Purchase Request # FD2030-15-02631 and the work requirements of the associated SOW titled “F108-200 Low Pressure Turbine Union of Assemblies MODULE #13/15 (Navy)”.

The FAA Form 8130-3 shall also identify the part number, serial number, work accomplished, and Service Bulletins complied with, reflected on all associated DD Form 1574 serviceable tags,. The contractor shall ensure that all reporting is accomplished as specified per the following Contract Data Requirements List’s (CDRLs) and corresponding Data Item Description’s (DIDs):

A001: Commercial Asset Visibility Air Force (CAVAF) Reporting A002: Contract Depot Maintenance (CDM) Production Report

A003: Comprehensive Engine Management System (CEMS) Reporting A004: Quality Deficiency Report (QDR)

A005: Supply Discrepancy Report (SDR)

A001: CAVAF Reporting - The contractor shall input the data IAW the CAVAF SOW guide. The contractor shall utilize CAV AF to track and report end items in repair by serial number when reparable is received and IAW CDRL DD Form 1423-1.

A002: Contract Depot Maintenance (CDM) Production Reporting (Monthly Production Reporting) - Data in accordance with the report format Source: https://assist.dla.mil – Downloaded: 2015-09-24T17:50Z (sample form attached to CDRL). Report shall not be waived. Data totals shall be as of the end of each month.

https://assist.dla.mil/

Contractor’s format with the same data elements as found on the CDM report may be accepted if approved through the PCO and IAW CDRL DD Form 1423-1.

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 and IAW CDRL DD Form 1423-1.

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) 734-4949, OC-ALC/ GKGBAA email: steven.gastineau@us.af.mil.

A004: Quality Deficiency Report - Deficiency Reporting is initiated on the occurrence when deficient Government assets are received by the Contractor. Contractor shall refer to T.O. 00-35D-54 using SF Form 368 and IAW CDRL DD Form 1423-1.

A005: Supply Discrepancy Report - This report enables the contractor to notify the Government when freight contents do not agree with shipping documents. In addition, the contractor shall submit Supply Discrepancy Reports (SDRs) when required IAW the contract’s CAV AF SOW, “End Item and Government Furnished Equipment Management,” Section 7. Contractor shall process Deficiency Reports when required IAW Section

1.1 of this PWS and IAW CDRL DD Form 1423-1.

1.13 Contractor Manpower Reporting: Contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the United State Air Force via electronic Contractor Manpower Reporting Application (eCMRA) a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil.

Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October of each calendar year. Contractors may direct questions to the CMRA help desk.

Uses and Safeguarding of Information: Information from the secure web site is considered to be proprietary in nature when the contract number and contractor identity are associated with the direct labor hours and direct labor dollars. At no time will any data be released to the public with the contractor name and contract number associated with the data.

User Manuals: Data for Air Force service requirements must be input at the Air Force CMRA link.

However, user manuals for government personnel and contractors are available at the Army CMRA link at http://www.ecmra.mil.

1.14 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.

1.15 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.

mailto:steven.gastineau@us.af.mil http://www.ecmra.mil/ http://www.ecmra.mil/

1.16 Preservation: The contractor shall not destroy reusable shipping containers, and will reuse them for return shipment. Units shall be packed IAW with T.O. 00-85B-3 using Special Packaging Instruction (SPI).

1.17 Shipping and Transportation:

Contractor shall meet the delivery schedule. Contractor shall ship or transport applicable deliverables as appropriate in order to have the deliverables available to support the customer’s operational requirements and in accordance with the contract’s delivery schedule. Contractor shall not destroy reusable shipping containers and shall reuse them for return shipments.

1.18 Contractor Identification to Government 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.

1.19 Safety: The Contractor shall maintain and execute a safety program using MIL-STD-882E, Air Force Instruction (AFI) and AFI 91-204 as guides. The Contractor shall comply with all safety provisions and technical specifications listed in CFM56 Engine Shop Commercial Maintenance Manual (CMM). All Contractor personnel and technicians shall comply with system safety engineering principles during all levels of remanufacturing.

While performing work under this contract the contractor shall comply with all applicable federal, state and local regulations regarding occupational safety and health. The contractor shall notify the PCO within eight (8) hours of any damage to Government Furnished Property (GFP) where the dollar value exceeds $500,000.00 and within two workdays, for any damage to GFP less than $500,000.00 during the execution of the contract.

Mishap notifications shall contain, as a minimum, the following information:

a. Contract, Contract Number, Name and Title of Person(s) Reporting

b. Date, Time and exact location of accident/incident

c. Brief Narrative of accident/incident (Events leading to accident/incident)

d. Cause of accident/incident, if known

e. Estimated cost of accident/incident (material and labor to repair/replace)

f. Nomenclature of equipment and personnel involved in accident/incident

g. Corrective actions (taken or proposed)

h. Other pertinent information

If requested by the designated PCO, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office.

1.20 Mission Essential Services: N/A

SECTION II

2.0 GOVERNMENT PROPERTY

2.1 Government Furnished Material (GFM): NONE. All parts and components required to accomplish the intent of the CMM, SOW or SBs shall be contractor furnished material.

Contractor furnished material and parts used for replacement shall be parts specified in CMM 75-21-30 Illustrated Parts List (IPL), SBs or as written approval from the AFLCMC/LPSBAB and/or AFLCMC/LPSBAA in writing through the PCO.

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

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 SB Service Bulletin SDR Supply Discrepancy Report S/N Serial Number SRAN Stock Record Account Number SS Service Summary SP Surveillance Plan SOW Statement of Work TAFB Tinker Air Force Base USAF United States Air Force

Enclosure 1

3.0 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.