FY25_T56-SIV_CIP_SOW.docx

NAVAIR

FY24 Statement of Work T56 Series IV Engine Component Improvement Program

June 28, 2023

1.0 Scope

The Propulsion and Power Component Improvement Program (CIP) provides resources to design, develop, and qualify engineering solutions to resolve and avoid safety, reliability, and maintainability deficiencies in operational United States Navy (USN) and United States Marine Corps (USMC) aviation Propulsion and Power equipment. This document is specific to contractor support activities for the T56 Series IV engine CIP.

2.0 Requirements

The contractor shall maintain an ongoing Research Development Technology and Engineering (RDT&E) program at the contractor’s facility and government facilities as required. The work scope for the Component Improvement Program is a series of projects known as Engineering Project Descriptions (EPDs). Each EPD shall be a standalone effort with unique cost, schedule, and deliverable(s). Examples of such efforts include hardware redesign, overhaul/repair techniques, support equipment/tooling design, hardware modifications, parts control and standardization program, and quality assurance program.

The following is a list and short description of the proposed projects. The complete EPD for each project is below.

EPD List

The contractor shall document and shall require all vendors to develop engineering data to support any newly designed or modified engine components, parts, and peculiar support equipment. Data shall be made available to the government within 30 days of request or within 90 days after a modification is released to service.

3.2 Engineering Data Documentation

The contractor shall document engineering design, material identifications, manufacturing processes, fabrication and assembly sequences, test procedures, acceptance test parameters, quality control procedures and acceptance parameters, and source data for purchased material with engineering data, for the life of the contract.

3.2.1 Contractor Furnished Equipment

The contractor shall maintain engineering data that defines every Contractor Furnished Equipment (CFE) item made as part of newly developed engine components and parts and peculiar support equipment furnished as CFE.

3.2.2 Government Furnished Material

The contractor shall maintain a record of all Government Furnished Material (GFM) pertaining to CIP efforts stored at contractor facilities.

3.3 Review of Engineering Data

The contractor shall host, support, and co-chair technical reviews of engineering data. Unless otherwise directed by the Contracting Officer, all documents, including subcontractor drawings, shall be delivered to the government. Additional engineering data reviews may be required when the number of deficiencies identified by the customer warrants such effort. These meetings will be scheduled as required by mutual agreement between the contractor and government. This requirement may be satisfied in conjunction with the Engineering and Program Status Reviews.

3.4 Provisioning Data

The contractor shall provide Engineering Data for Provisioning (EDFP) and Provisioning Technical Documentation (PTD) which identify changes/improvements resulting from the CIP and/or other customer approved engineering changes and submitted under the original contract.

The contractor shall conduct and facilitate informal engineering and program status reviews. The contractor and government shall agree upon the location, schedule, and content. These informal reviews are a forum for the government and contractor to review technical, financial, and procurement status. Any programmatic changes agreed upon at the review that affect funding are not valid until completion of a contract modification to implement the change.

4.2 Annual Formal Review

The contractor shall present a formal review to the USN and International Engine Management Program (IEMP) member country representatives who have contributed to Series IV CIP. The formal review shall address status of CIP activities for which they have contributed. The contractor and USN representatives (including T56 SIV FMS case managers) shall agree upon the location, schedule, and content of the formal review. The contractor may present slides at the annual IEMP event with government attendees on the phone and/or in-person. Alternatively, this review may coincide with one of the Engineering and Program Status Reviews described in 4.1, by inviting member countries to one of these reviews virtually or in-person.

Engineering Project Descriptions

EPD 5641.1.31 SIV Program Contract Management:

Program Description:

The T56 Series IV Component Improvement Program provides the designs, material costs, testing and reporting of engineering changes for Series IV engines. To ensure program success, program management support is required.

Objective:

Oversee the CIP Program by successfully executing the assigned EPD projects and tasks. This also includes executing the CIP program to the established cost, schedule and contractual requirements. Program Contract Management should also cover all necessary communication with the Navy to provide program execution plans/status, identify program deficiencies/corrective action, and address any contractual concerns.

Statement of Work:

Manage the engineering, logistics, material, testing, and programmatic activities within the Component Improvement Program to ensure that all technical, schedule, and financial goals of the T56 Series SIV CIP are achieved. Manage project activities, logistics, cost, schedule, testing, and material. Provide CDRL deliverables and project reports. Support CIP meetings and review of Engine Management Plan (EMP) elements. Manage government owned CIP property at contractor facilities.

Assumption: This no longer covers Navy Day and Chief Engineer calls Assure that the expected meetings are held:

· Three (3) CIP Manager’s Meetings

· No full-team IEMP event participation. Contractor shall present a limited presentation to international participants (T56 SIV CIP contributors only) at the IEMP. Content and attendance shall be agreed upon between contractor and USN (including FMS case managers). International participants may be invited to one Manager’s Meeting virtually or in-person in lieu of this.

· Bi-weekly technical calls

· Monthly CIP financial expenditure plan and progress meetings

· Ad-hoc meetings and teleconferences as needed (i.e. EMP goals, EMP review) Deliverables:

1. CIP Expenditure Report – Monthly (CDRL A007)

2. CIP Expenditure Plan and Progress Briefing – Monthly (CDRL A003)

3. CIP Management Review – Tri-Annually – April, July, October (CDRL A003)

4. Contractor's Year-End Progress, Status and Management Report – Annually (CDRL A004)

5. Product Drawings and Associated Lists – As required (CDRL A005)

6. Government Furnished Material (GFM) Report – Annually - December (CDRL A008)

7. T56-A-427 and T56-A-427A Major and Minor AEMs – As required (CDRL A001)

EPD 5641.1.31A Series IV New Project Development:

T56 SIV CIP development of new and existing projects to improve reliability, reduce cost of ownership/operation, improve safety and other metrics to meet US Navy engine goals.

Objective:

The objective of this EPD is to systematically elicit ideas and progressively down-select projects that aim to improve T56 SIV platform metrics (cost, safety, reliability, readiness, maintainability, etc.). Contractor and USN will develop projects using data from USN reliability studies, ACI results, SRDs and other investigations. Projects with that have gained approval through the USN Propulsion and Power milestone review process will take precedence.

Statement of Work:

Contractor shall work with USN to develop new and existing T56 CIP and Reliability Centered Maintenance efforts. Contractor shall provide deliverables/research packages that contain estimates for technical work scope, schedule, rough order of magnitude (ROM) cost, and assist in assessing program impacts (reliability, maintainability, cost, safety, etc.) for each EPD. The following work shall be coordinated through technical calls and dedicated sessions at CIP manager’s meetings:

· At the July (Summer) CIP Manager meeting: Contractor shall identify and discuss potential USN projects for the following CIP year (current CIP year + 2) to help maintain a five year budget plan.

· At the October (Fall) CIP Manager meeting: Contractor shall provide a Preliminary Research Package based on the EPDs discussed at the July CIP review for the following CIP year (current CIP year + 2) for all new and continuing projects.

· At the April (Spring) CIP Manager meeting: Contractor shall assist in the down-selection of new projects for the upcoming CIP year (current CIP year + 1) and provide a Final/Heavy Research Package prior to the April CIP review.

· Contractor shall generate detailed proposals with basis of estimates (BoEs) for the upcoming CIP year (current CIP year + 1) in response to delivered Request for Proposal (RFP) and Statement of Work.

· Contractor shall provide ad-hoc cost and schedule estimates as needed to support EMP development throughout the year, and suggestions for small tasks / service revealed deficiencies as they occur.

Deliverables:

1. Final/Heavy Research Package for CIP 2025 (CDRL A00A) – 7 days prior to April CIP Manager’s meeting

2. Formal Proposal for CIP 2025 (CDRL A00A) – Q3CY24

3. Preliminary Research Package for CIP 2026 (CDRL A00A) – 7 days prior to October CIP Manager’s meeting

4. NAVY will provide summary level of mission readiness and reliability data (IFSD, LOTC) and list of MTBR and removal reasons for the propulsion system and all LRU on a quarterly basis.

5. NAVY will provide courtesy copy of the ‘T56-A-427A Engine Management Plan’ annually

6. NAVY to provide ‘2026 Request for Quotation’ and ‘FY26 Statement of Work’ in June to enable adequate time for the response, negotiation, and contract award by 1 JAN 2025.

EPD 5641.1.60 SIV Fleet Leader ACI:

Program Description:

Execution of Analytical Condition Inspections (ACIs) of fleet hardware or select components to identify impending failure trends before they are a driver. This EPD allows the team to take a proactive stance with future CIP projects and Fleet Service Team (FST) initiatives. Additionally, induction runs allow the team to relate hardware condition and operational usage to performance.

Objective:

To identify components or drivers that impact engine/module metrics through hardware inspections, maintenance database searches, and collection of other relevant data. This information will be used in consideration for future projects or efforts. The USN will identify engines/modules throughout the period of performance for ACIs and additional engines for induction runs only. Once the engines/modules are identified, the contractor shall provide engineering support, including estimates of cost and schedule, to complete work.

Statement of Work:

For up to four engines specified by the USN, the contractor shall conduct an induction run to determine engine health prior to repair.

For two ACI candidate engines/modules specified by the USN, the contractor shall support an investigation of the hardware, including onsite participation from USN and contractor component subject matter experts (SMEs). In support of the ACIs:

· Contractor shall provide technical, cost, and schedule updates to the USN on a monthly basis.

· Contractor and USN engineers shall collaborate to develop special inspection and measurement sheets for each module to supplement the routine overhaul inspection and measurement sheets.

· Contractor shall inspect and measure features as specified by USN and the special inspection/measurement sheets on the selected service modules/engines.

· Contractor shall provide special inspection data for each module/assembly to USN and contractor SMEs.

Note: Only the analytical condition inspection efforts above and beyond data collected during routine overhaul processes shall be charged to this EPD effort.

Deliverables:

1. Presentation Material – Project Technical, Cost, Schedule Update (CDRL A003)

2. Test Report – Engine Induction Test (CDRL A006)

EPD 5641.1.40A SIV Service Revealed Deficiencies:

Investigations of Service Revealed Deficiencies (SRDs) found in the fleet and support of CIP tasking prior to maturity into a contractually defined project. This allows a timely response to USN inquiries without setup and execution of a unique EPD.

Objective:

The objective of this EPD is to provide contractor engineering support of SRDs and/or execution of small-tasks (including those not aligned with a specific EPD) as identified by USN CIP manager/Basic Design Engineer (BDE). This includes support of root cause and corrective action activities led or directed by the USN. These efforts will culminate in Engineering Department Reports (EDRs) when applicable.

Statement of Work:

SIV Service Revealed Deficiencies: Contractor shall perform a detailed investigation against T56 Series IV SRDs as directed by an Engineering Coordination Memorandum (ECM) containing a SOW from the USN. Contractor shall deliver all SOW-requested data, information, findings, conclusions, and recommendations in an EDR to the USN within 180 days of the submittal of the ECM. Contractor shall provide cost and schedule estimates to complete requested SRDs, and maintain a list of SRDs in monthly financial reporting.

Assumption: The level of effort is level loaded and consistent with historical averages, envisaged as three medium size efforts each of four months duration.

Deliverables:

1. Presentation Material – Project Technical, Cost, Schedule Update (CDRL A003)

1. Engineering Department Reports (CDRL A002) EPD 5641.1.40B SIV Small Tasks:

SIV Small Tasks: Contractor shall execute miscellaneous technical work (designated as “small tasks”), that support achieving the platform metrics (cost, safety, reliability, readiness, maintainability, et.) including those not aligned with a specific EPD that arise throughout the period of performance, and provide engineering reports as needed. Examples of known non-specific EPD tasking is as follows:

· Performance Management

· ASMET/eASMET initial test planning/discussions and knowledge pass through

· Discuss requirements to conduct testing at RR facilities

· Nacelle Temperature Study

· Investigate metal in oil driven removals Contractor shall provide cost and schedule estimates to complete requested SRDs and Small Tasks, and maintain a list of tasks on monthly financial reporting.

Deliverables:

1. Presentation Material – Project Technical, Cost, Schedule Update (CDRL A003)

1. Test Report - As Required (CDRL A006)

1. Engineering Department Reports – As Required (CDRL A002)

1. Meeting - Performance Management – Monthly (CDRL A003)

EPD 5641.1.69 AHE Control System Software Update – Inadvertent AutoFeather, T5:

Advance Hawkeye (AHE) contains an autofeather system. This system is known to be inadvertently triggered when the system is armed and rapid advancement of the power levels from near flight idle occur. This can cause RPM decay well below the normal governing range causing an uncommanded engine shutdown. A FY22 PCMU software development effort, T4.0.2 (IR 35672), provides a degree of mitigation in regard to sensor errors that can complicate this scenario. However, from examining other autofeather events, and feedback from an autofeather mishap, there is NAVAIR leadership direction to evaluate and develop additional mitigations.

Objective:

The objective of this effort is to develop potential software requirements for a follow-on build, identified as T5, that addresses a broad set of improvements drawn from a few of fleet autofeather incidents and the 2022 mishap. The FY23 effort kicked off T5 by developing related solution strategies for inadvertent autofeather and conducting planning activities. In FY24 continue to develop solution strategies for non-inadvertent autofeather content identified by rack and stack. Develop cost and schedule impact with knowledge of content prior to entering implementation phase. In FY25 the goal of this project will be to finalize the build of T5 and conduct system and software validation and verification activities. These will include running the software build across the RR RTS and the NGC SIL, in addition to these efforts, if schedule and funding permit, conduct ground test runs and flight test to finalize the software for production release. Of note, this task also addresses development of NATOPS and source material for IETMS and other Navy documents related to these changes and other autofeather/sub-idles event investigations.

Statement of Work:

1. Program and Technical Management

a. Provide engineering support as needed through the ECP implementation process

b. Host ad-hoc working group level meetings to review program progress, technical issues, projected work, earned value and other relevant updates as required

2. Conduct system and software validation for T5 build

a. Finalize build of T5 from solution strategy set

b. Conduct system and software verification of T5

c. Establish a test plan for T5 and capture in a planning document

d. Provide engineering release for testing as required

e. Conduct engine test with a prop (if possible)

f. Conduct flight test

3. Associated operation and maintenance documentation

a. Provide any associated recommended updates to NATOPS, maintenance and related publications Deliverables:

1. Presentation Material – Project Technical, Cost, Schedule Update (CDRL A003)

a. Integrated Detailed Master Schedule

b. Ad-hoc Progress Status Updates

2. Updated data items, and related documentation to support audits, including Software Files to be loaded on PCMUs (CDRL A001)

3. Engineering Department Reports as defined by the T56-A-427A Software Liaison Plan (CDRL A002)

a. T5 Planning Document

b. T5 Validation plan

c. T5 test readiness audit

d. T5 ground test release

e. T5 flight test release

f. Recommended NATOPS, FIM, IETMS changes

EPD 5641.2.04 E-2D Life Update:

Changes in hardware, mission, analysis methods, and fleet distribution can affect life calculations rendering limits based on previous data obsolete. The previous rotor life update was published in 2011, since then there have been updates to Rolls-Royce best practices and modeling capabilities. In addition to these updates, the previous analysis utilized non-continuous E-2C Electronic Analyzer Unit (EAU) data from flights recorded during 2001-2004 timeframe, this analysis will look to take into account the higher fidelity E-2D data, collected within the past few years.

Objective:

The AHE rotor life update will look to update the lives of the critical rotating parts in the turbine first. Expectation is there will be a continuation of this effort to update the lives of the compressor. The goal of this effort is to update the Low Cycle Fatigue crack initiation and crack propagation lives, taking into account the E-2D operating spectrum.

Statement of Work:

Assumption: The models will be updated to the latest Rolls-Royce standards and then evaluated against the new Mission Mix.

Assumption: A new Mission Mix or Mission Profile will be provided to Rolls-Royce from the USN no later than December, 2024.

1. Rolls-Royce shall re-assess the component lives of the -427A turbine hardware using the updated models (thermal, stress, etc.) and mission mix.

a. Determine if there are any benefits to changing the current lifes of these parts

2. Rolls-Royce shall update the lifing documents as necessary

Deliverables:

1. Presentation Material – Project Technical, Cost, Schedule Update (CDRL A003)

2. Engineering Department Reports (CDRL A002)

3. AEMs (CDRL A001)

EPD 5643.4.07 SIV Fuel Nozzle Coking Reduction:

The current fuel spray nozzle design implemented on the T56-A-427 and -427A engines frequently develop carbon coking on the interior fuel passages of the secondary body due to temperatures in excess of the fuel’s vaporization point. Coked fuel nozzles have been linked to multiple engine removal causes including failed 800hr TIT check, loss of material on crossover tubes, and degraded turbine blades/vanes. Current RCM mitigation efforts to replace all fuel nozzles at depot have been unsuccessful at decreasing engine removals linked to fuel nozzle coking, and cost significantly more than the previous cleaning/overhaul procedures.

Objective:

This project aims to develop and implement a fuel nozzle design or cleaning procedure that can effectively mitigate coking related engine removals and eliminate the need to replace all fuel nozzles at depot.

Statement of Work:

Assumption: Effectiveness of retrofit heat shielding must demonstrate sufficient heat protection to be considered for implementation.

1. Demonstrate capabilities of fuel nozzle heat shield design for consideration of fleet implementation.

a. Evaluate test results from burner rig test.

i. Confirm improvement of wetted wall temperatures of redesigned nozzle.

b. Create test reports (TDR and EDR).

2. Conduct vibration test of fuel nozzle heat shield design to ensure no reduction in life.

a. Create test report (EDR)

3. Provide AEM for approved redesign of nozzle.

Deliverables:

1. Presentation Material – Project Technical, Cost, Schedule Update (CDRL A003)

2. Engineering Department Reports (CDRL A002)

3. Rig Test/Inspection Report (CDRL A006)

4. AEMs (CDRL A001)

EPD 5646.1.1.05 Prop Shaft Repair:

Program Description:

The carrier based T56 platforms E-2C/D fleets do not have a qualified repair process to restore damaged/corroded prop shafts. Other USN T56 applications use a chrome plate process allowing re-use rather than disposal of a high-dollar engine component. Per ACI data, an average of 80% of prop shafts (P/N 23079161) have been rejected with 35% being repairable. The USN desires a repair process on the E-2D fleet to leverage cost savings in engine repairs. This repair process would only be applicable to RGBs with AHE prop shaft (P/N 23079161) installed. A viable method of checking/testing repaired hardware will need to be used to assure a 100% quality process. As part of the USN “green effort” to eliminate Hazardous Materials aspect of applications/stripping of chrome plate repair, the USN wants to replace the chrome plate repair with tungsten carbine plating repair procedures.

Objective:

Develop/verify/obtain approval and publish a book repair method to successfully repair AHE prop shafts (P/N 23079161):

The following milestones should be achieved in 2025:

· Complete remaining qualification testing (4 hour overload test)

· Publish all EDRs associated with previous efforts and any previous testing

· Develop and deliver AEM with associated repair procedures to the U.S. Navy Statement of Work:

Assumptions: Testing commences in 2024. Metallurgical evaluation is not required. Schedules assumes similar durability of test stand.

1. Following completion of endurance test, complete 4 hour overload test

a. Conduct teardown and inspection to status hardware at conclusion of testing

2. Evaluate test results.

3. Create MPI and NDT for Prop Shaft to be used for repair substantiation

4. Create test reports (TDR and EDR).

5. Update and release book repair document.

Deliverables:

1. Presentation Material – Project Technical, Cost, Schedule Update (CDRL A003)

2. Engineering Department Reports (CDRL A002)

3. Repair Procedures (CDRL A00B)

4. Test/Inspection Report (CDRL A006)

(Option) CIP2023-05 AHE FMECA and SAR Update: Scope for half a year, can delete if can’t make work

The AHE FMECA and SAR Update supports the SIV team’s regular assessment of 427 and 427A FMECA and engages OEM support for formal update. The SIV team will incorporate findings from Red Tops, AEMs, and previously unconsidered real-world effects into maintaining an updated FMECA.

Objective:

Develop an updated FMEA/FMECA for use by the US Navy to consider newly found failure modes and updates in hardware. This goal of this update is to consider all changes since the last update to provide current failure modes and effects for current hardware to assist in creation of criticality determinations and risk assessments.

Statement of Work:

Assumptions: Project planned over a 2-year timeframe Assumption: A new all AHE encompassing EDR will be created and published. Work will be based on previous FMEA/FMECA updates Assumption: New effects not previously described will be added as necessary Assumption: Probability of failure is not required, engine effect only Assumption: Output data format will be useable by US Navy (pdf/excel)

1. Create new FMECA for -427A rather than having a delta FMECA

a. Consolidate existing data into one FMECA for all AHE engine and control system

b. Update to current understanding based on Red Tops, Risk Assessments, and Engineering Investigations

c. Update to include AEMs from new parts, ensure not missing parts from current parts list Deliverables:

1. Presentation Material – Project Technical, Cost, and Schedule Update (CDRL A003)

2. Engineering Department Reports (CDRL A002)

a. New FMECA (with new EDR) for -427A (PDF/excel)

(Option) CIP2023-08 SIV SLAM: - Scope for half a year, can delete if can’t make work

The Structural Life Analysis Management (SLAM) provides a single source for life management data. It will be used as input to the US Navy Life Management Plan (LMP) along with current open project E-2D Life Update. The SLAM document is intended to supersede EDRs and mitigate unnecessary complexity by reducing the amount of required documents needed for adequate life management tracking.

Objective:

This project aims to publish a SLAM for input to the US Navy LMP.

Statement of Work:

Assumption: Compressor Engineering Critical Parts Plan (ECCP) for 2025 will not include new lifing mission/analysis (won’t yet be completed) a. Would be included in a 2026 SLAM update, if funded Assumption: Recurrence of this effort will be every 3 years or when there is a major change in mission mix or change to hardware that would impact component lifing.

RRC will create a Structural Lifing Analysis & Management (SLAM) to combine the engineering information for critical components/sub modules into one document. The initial task will be to create an Engineering Critical Parts Plans (ECPP) for the T56-SIV critical components. The SLAM will be created by using the ECPPs and researching other available reports (EDRs, TDRs, LMPs, …). Three ECPPs will be issued for each series. There will be an ECPP for the turbine module (including turbine disk & spacers), compressor module (including all wheels) and gearbox (RGB) module (including Propeller shaft, main drive gear, & input pinion gear).

The content proposed for the SLAM report is as follows:

1. General description of the application

a. USN training application

b. Significant operational/developmental history notes

2. General Description of the engine and operation

a. Major Components/Modules

i. Prop Shaft/Gearbox

ii. Compressor

iii. Turbine

b. List of lifed and non-lifed critical parts by part number

3. Discussion on RR lifing methodologies and application to T56-A-427/A engine

4. For each module / critical part

a. Mission profile definition

b. Performance, Thermal, and Stress models and results used in life analysis by module

c. Analysis standard employed

d. Including summary of test data used to support life

e. Critical LCF features & stress distributions

f. Areas sensitive to damage

g. Areas insensitive to damage

h. Crack Initiation Lives (where available) for critical locations

i. B50%

ii. B0.135% (50% and 95% Confidence)

iii. Mean and 95% confidence LCF lives

i. Crack Propagation Life (where available) for critical locations

i. B50%

ii. B0.135%

j. Any other useful historical information

5. SLAM shall include all necessary data to support US Navy LMP and planning activities

a. Recommended module testing

b. Inspection information

c. Current and future improvement activities

d. Manufacturing and product engineering memos affecting more than 10 serial numbers of a given part number for critical components

Deliverables:

1. Presentation Material – Project Technical, Cost, and Schedule Update (CDRL A003)

2. Engineering Department Reports (CDRLA002)

a. New SIV (-427A only ) SLAM

ECP Kit Parts Buy:

Following the completion of engineering efforts to identify and design solutions to fleet problems there is a need to purchase those parts for incorporation into the fleet. This project will be used to quote and purchase those follow on parts.

USN E-2D fleet incurred three non-recoverable inflight shutdowns (IFSD) due to a failure of a union on the Accessor Dreiving Housing Assembly. Following these events a root cause analysis was conducted and determined that these parts failed in HCF due to low margin of the aluminum material. Following this investigation, it was determined that a steel fitting would increase the margin, reduce the failure mode, and allow for the removal of the required 800 hour inspection that was incorporated following the events. This effort will be to purchase this steel fitting to support the needs of the fleet.

Objective:

This line item will be used to purchase parts/kits to support the incorporation of completed CIP efforts that have approved ECPs.

Statement of Work:

1. Purchase the required number of parts to support the incorporation of the new AGB Union design in the fleet. Based on feedback from Logistics the need is for 115 parts.

Deliverable:

CDRL for tracking delivery