KC HSM Statement of Objectives DRAFT6.3.pdf

Statement of Objectives For

Eaton Aerospace In support of

KC-135 Hydraulic Start Motor (HSM) redesign December, 2019

Version # Contract: TBD

BACKGROUND

The KC-135 Auxiliary Power Unit (APU), part number 161331-135A, provides compressed air and generates electrical power for starting aircraft main engines and running aircraft systems. It is initially driven by a Hydraulic Start Motor (HSM), which uses pressurized hydraulic fluid to turn a series of pistons, creating rotational torque to start the APU.

The original design of the HSM is governed by a specification (Turbomach ESR0052) which is called out on the Source Control Drawing (UTC, formerly Solar Turbines, CAGE 55820) 161794. Two qualified sources are listed on the Source Control Drawing (SCD): Garrett Hydraulics (became Honeywell, who sold the data rights to Triumph Actuation Systems (Clemmons, NC division) in the late 1990s), and Sperry Vickers (became Eaton Aerospace LLC). Garrett/Honeywell manufactured 900+ units which are currently fielded.

Condemnations of HSMs that were beyond economical repair eventually drove a need to purchase relatively small quantities of new assemblies. Eaton Aerospace LLC was the only bidder on the solicitations, and consequently won the bids.

The government does not own any rights to any manufacturing level drawings for either version of the Hydraulic Start Motor nor drawings for any of its internal components.

Eaton’s version of the Hydraulic Start Motor appears to meet the minimum specifications outlined in SCD 161794 & ESR0052. However, USAF experienced two catastrophic failures (fractured housings) of the Eaton HSM in 2017. Both incidents occurred in the APU test cell, and the root cause investigation revealed that failure to charge a surge damper in the hydraulic supply line was the most likely contributor to pressure spikes inside the start motor housing. A relatively small number of Eaton HSMs have been fielded, and fortunately, no failures have occurred on aircraft.

Risks include the potential of personnel injury and equipment damage both in the test cell and on the aircraft. These risks are mitigated by several factors, including containment apparatus and standard procedures (isolated test cells, APU cabinet doors on aircraft, safe starting procedures, etc.)

The Air Force recognizes the need to eliminate this HSM issue in order to avoid negative impacts on mission capability.

Pratt & Whitney AeroPower (formerly Hamilton Sundstrand, Solar Turbines, Turbomach, etc.) is the only historical provider of the KC-135 APU and is the only company that has the proprietary data to make changes to the existing APU assembly, as well as the proprietary data to govern APU hydraulic start motor performance. They also have an extensive knowledge of the design requirements needed for aircraft-mounted engine start systems. However, the company outsourced the design of the Hydraulic Start Motor for their APU.

Triumph Actuation Systems has not bid on any of the solicitations, and is therefore not considered an active source of supply.

Eaton Aerospace is the only current provider of the Hydraulic Start Motor, and owns the proprietary data to make changes to the assembly and any of its subcomponents. They also have an extensive knowledge of the design requirements needed for aircraft-mounted start systems.

PURPOSE

The purpose of this SOO is to request an Engineering Project Description (EPD) and cost quote that details the work and time required to analyze and improve the safety factor of KC-135 Hydraulic Start Motor (HSM), and necessary associated tasks.

We suggest a phased approach to this project:

The first phase should include assembly and instrumentation of a test setup at FRC-East (Cherry Point MCAS: Navy facility in Havelock, NC where APU is overhauled and tested) to replicate the configuration which caused the failures, and additionally to mimic aircraft configuration. This test set up and instrumentation will be used to collect pressure data. The contractor would need to supply appropriate pressure transducers for high rate data capture. USAF will supply solenoid valves to match current APU test cell and aircraft configuration (APU test cell valve speed: 0.04 second; Aircraft valve speed: 0.10 second).

This data collection effort will require travel of Eaton Aerospace personnel for test setup and data collection.

The main deliverable for the first phase of the project will be a Report, written by the contractor, which details the data collection and analysis, and which provides Recommendations based on the analysis.

The other main deliverable for the first phase of the project will be the delivery of a Contractor-edited government-owned overhaul manual, based on the U.S. Army DMWR 1-2995-235 (HH-60 APU HSM).

Overhaul and repair data includes disassembly, cleaning, inspection, repair, assembly, and testing requirements, as well as an illustrated parts breakdown and a detailed list of special tooling and fixtures required for complete overhaul and testing.

The second phase should consist of redesign solution implementation, based on findings, recommendations, and decisions from the first phase, and which would possibly include a rewrite of the specification governing the HSM design. This second phase will most likely include a stress analysis of the existing Motor Housing to evaluate stress concentrations and possible failure points. Based on the two failures experienced, one necessary improvement will be more shallow machined radii in the area of the center flange to reduce crack initiation points or a change in material. Other options may present themselves as the analysis is conducted. Failure hardware will be available for Eaton to examine in this process.

If a redesign solution were to include a redesign of the Motor Housing casting, the USAF would also suggest a redesigned center flange which makes housing thickness more uniform across split line, and a narrowing of the cross-section to allow for aircraft fit without interference from the aircraft fire detection system (detailed in Source Control Drawing 161794 and USAF EO 17C0102-H). Details of this fit requirement will be provided at the start of phase 2. Phase 2 will also include delivery of final report, Design Reviews, and drawings.

The third phase will include qualification testing. In order to provide this testing, prototype hardware will need to be delivered. A quantity of 2 prototype start motors will be required for testing purposes and APU & aircraft fit checks. It will also include delivery of final reports with an Engineering Change Proposal (ECP).

The requirements listed in the SOO are expectations that the government has for a successful program.

There may need to be further explanation for the contractor to complete the proposal. There also may be some items that the government has unintentionally omitted. In these cases, the contractor will contact the contracting officer for further explanation.

Eaton should initially quote for phase 1 only and use the remaining work scope (phase 2 and phase 3) for planning purposes. The scope listed for phases 2 and 3 are just suggestions at this point and may change upon completion of phase 1. The follow-on years will require an updated SOO provided with Eaton input to ensure we capture all requirements necessary for a successful program.

Use the accompanying Performance Work Statement to help detail and define the requirements.

SCOPE/MISSION

The scope of this HSM redesign solution shall include the following:

• Final HSM assembly must meet or exceed all original specifications outlined by Pratt & Whitney (ESR 0052) as well as fit dimensions detailed in SCD # 161794 and applicable USAF EO 17C0102- H

• Develop a solution that allows for range of possible hydraulic pressures

• Eliminate catastrophic failure issue related to the HSM housings

• Incorporate any feasible maintainability improvements

• Scope will include the normal tasks required to qualify new hardware (e.g. part number assignment, testing, qualification, ECP, etc.)

• Testing of design solution shall consist of motor assembly pressurization using situational criteria that caused original failures (un-damped 3000 psi surge, using equivalent valve actuation speed)

• Qualification of redesign should be done by simulation/analysis and test, validated by testing described above

• Coordinate design process through 419 SCMS Engineering and provide monthly (or as required) updates on project status

• Provide qualification hardware (recommend at least 2 Starter Motor assemblies)

• Provide required reports (Qualification, Test Plane, Test results, PDR/CDR report, year end reports, etc.)

• Hold required reviews: combined Preliminary Design Review (PDR) & Critical Design Review

(CDR), Test Readiness Review (TRR), etc., as applicable

• USAF Technical Orders for overhaul and repair, to include detailed instructions for disassembly, cleaning, inspection, repair, assembly, and testing requirements, as well as an illustrated parts breakdown and a detailed list of special tooling and fixtures required for complete overhaul and testing

• Identify, develop and submit any changes to support equipment if required

PERIOD OF PERFORMANCE

Timely completion of this effort is required. Contract execution will begin immediately upon contract award. Based upon the estimated scope, each phase should be one-year efforts. The Period of Performance (POP) for this effort is expected to be one year after receipt of order.

DELIVERABLES

Phase 1

• A001- Engineering Project Description (This is the initial quote for phase 1), Phase 2 EPD will be required at the end of Phase 1

• A017- Technical Publication Requirements

• A020- Support Equipment Data (For TO review)

• A003- Test Plan

• A004- Test Results Report

• A002- Final Phase Report

• A015- Integrated Master Schedule (Tailored and Updated)

• A012- Agenda

• A013- Meeting Minutes

Phase 2

• A015- Integrated Master Schedule (Tailored and Updated)

• A012- PDR/CDR

• A014- Meeting Minutes

• A019- Final Drawings Package

• A007- Airworthiness Specification

• A002- Phase 2 Report

• A001- Phase 3 EPD

Phase 3

• A015- Integrated Master Schedule (Tailored and Updated)

• A018- Engineering Change Proposal

• A003- Qualification Test Plan

• A008- Airworthiness Certification Report

• A012- Test Readiness Review

• A014- Meeting Minutes

• A004- Test Results Report

• A018- Engineering Change Proposal

• A002- Final Report

• Hardware

SCHEDULE

The Integrated Master Schedule (IMS) will be delivered 30 days after the contract is signed and updated regularly per the CDRL. A kickoff meeting will be held within 3 weeks of contract award. The project team will consist of personnel from the contractor(s) and the government. The contract deliverables as stated above will be per the IMS. All deliverables will be sent IAW Contract CDRL for the Government to review and give concurrence before acceptance. As discussed above, the Period of Performance (POP) for this effort is expected to be one year after award. A contract modification will be required to extend, upon the request of the contractor.