3_-_ENGINE_SOW_MT.docx

1.0 Introduction & Background

The National Aeronautics and Space Administration (NASA) operates a Boeing 747SP aircraft as an airborne astronomical observatory under the Stratospheric Observatory for Infrared Astronomy (SOFIA) Program. This aircraft N747NA S/N 21411 is operated by NASA Armstrong Flight Research Center (AFRC) and is located at Palmdale, CA.

The SOFIA aircraft is a Boeing 747SP. It was originally acquired by Pan American World Airways and was delivered in May 1977. In February 1986, United Airlines purchased the plane. United removed it from active service in December 1995, and it was purchased by NASA in 1997. The aircraft was substantially modified for its new role as a flying astronomical observatory by L-3 Integrated Systems of Waco, Texas. To ensure proper modification, a dismantled section from another 747SP was used as a full-size mock-up.

The Stratospheric Observatory for Infrared Astronomy (SOFIA) consists of a specifically configured 2.5-meter diameter Telescope Assembly (TA) mounted inside the aircraft. The telescope observes space-based objects through a large articulating open port in the upper left-hand quadrant of the aircraft fuselage aft of the wing. A pressure bulkhead separates the un-pressurized telescope optics compartment from the forward passenger cabin; the telescope extends through this pressure barrier with the science instrument mounted in the pressurized passenger section, providing hands-on access to the investigators.

APU P-37735 44,212.10

2.0 Objective and Scope

Engine Serial Number P695768 has a Turbine Exhaust Case crack that requires replacement per the maintenance manual. The crack measures 3.5” forward of the R-flange and 2.2” aft of the R-flange. The crack extends through the flange, through the fillet radius, and along the case. Additional borescope inspections inside the inspection plug show the crack through the case wall.

Contractor shall perform the following:

· Provide a new exhaust case.

· Provide disassembly, assembly and labor required to replace the exhaust case.

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

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

· Perform Water Wash In Accordance With (IAW) P&W EM 72-00-00 Engine General Cleaning-02 (Engine Gas path Cleaning)

· Perform AD 2009-04-18 Inspection Vane and Rotor Contact.

· Perform “C” check inspection IAW Boeing AMM 747-72-31-00/601 through 72-31-07/601

· Perform engine TEST # 20 IAW Pratt and Whitney Engine Manual

· Review and update all engine documentation based on provided repairs by this Statement of Work SOW and submit to NASA.

· Update all Time Since New (TSN), Cycles Since New (CSN), Time Since Repair (TSR) records and submit to NASA.

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

· Review of repair records.

· Review last Test Cell report.

· Review Engine Condition Monitoring (ECM) Report.

· Review aircraft and maintenance logs for reported discrepancies and repetitive inspection defects.

· Prepare engine for shipment.

3.0 Work Requirements/Deliverables

· Provide NASA a detailed assessment for JT9D-7J SN P695768 engine.

· Life Limited Report including TSR, TSN and TSO of the engine module

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

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

· Provide detailed engine performance test report from Test #20.

· Provide a detailed summary of incorporated AD’s / SB’s and recommendations for the implementation of all outstanding AD’s / SB’s

· Provide a FAA 8130.

· Provide a detailed recommendation for assessed engine repairs for continued airworthiness

4.0 QUALITY ASSURANCE.

The Contractor shall provide and maintain a AS9100 certified Quality Management System. The Contractor’s inspection program shall ensure compliance with technical guidance, engineering specifications, and EASA/FAA regulations applicable to JT9D maintenance. Documentation shall be required for traceability, accountability, and a historical record of design, testing, inspection, qualification, and acceptance of all materials and components.

4.1 Quality System: The Contractor shall possess current FAA Repair Station certification to 14 C.F.R. Part 145 for engine maintenance. A certified repair station must establish and maintain a quality control system acceptable to the FAA that ensures the airworthiness of the articles on which the repair station or any of its contractors performs maintenance, preventative maintenance, or alterations.

4.2 Suppliers: The Contractor shall be responsible for Quality Assurance of vendors, suppliers, and subcontractors providing services under this contract to verify compliance with accepted standards. For those vendors who provide FAA certified parts and services, a copy of the valid certification shall be made available to NASA.

4.3 Non-conformance: The Contractor shall have in place a procedure for reporting of nonconforming articles, materials, and equipment. (“Non-conformance” is defined as a condition of any article, material, or service in which one or more characteristics do not conform to the specified requirements. This includes failures, discrepancies, deficiencies, defects, anomalies, and malfunctions).

4.4 Inspection: The Contractor shall provide inspectors to verify that work is performed in accordance with technical specifications and the documentation is completed in accordance with the Pratt and Whitney maintenance manual.

4.5 Tool Control: NASA requires the Contractor to utilize a system of positive tool control, including (but not limited to) shadowing of toolboxes. Contractors not in compliance with this requirement shall propose an alternative method of tool control.

5.0 CONTRACTOR QUALIFICATION REQUIREMENTS

The contractor shall certify (and/or provide evidence where required) that the following requirements are met, or where requested, propose an alternate approach.

5.1 STAFF EXPERIENCE . NASA requires that all technicians performing this maintenance are EASA/FAA Airframe or Power plant (A&P) certified for work on this engine type. Technician assistants with proper oversight do not require this certification.

5.2 TOOLING. The Contractor shall certify that they possess or can obtain (prior to commencement of this effort) all fixtures, tooling, and support equipment necessary to perform the required engine maintenance. NASA will not provide any tooling or support equipment.

5.3 “ONE-STOP SHOP.” All work shall be performed at the same location. The engine shall not be moved to a subcontractor facility to complete the work or engine run.

5.4 REFERENCE MATERIALS. The Contractor shall possess all of the relevant JT9D technical reference material to perform this task except those provided by NASA.

5.5 SECURITY. The Contractor shall provide badged access restrictions to the facility that houses the engine to ensure that only authorized maintenance personnel have access to the engine.

5.6 Recognized as a Designated System Provider (DSP) for JT9D engine maintenance and overhaul services by Pratt & Whitney

5.7 Must be compliant with all PWGSP QA101 requirements

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

5.7.2 The contractor works closely with Pratt & Whitney Core Quality to ensure that the shop remains Audit Compliant, and there are regular quarterly meetings/reviews supporting these efforts.

6.0 Other Requirements

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

6.2 Test #20 oversight: NASA shall have the option to witness the Test #20 operation.

6.3 Warranties: The Contractor shall submit, and recover whenever possible, warranty claims for the Government for parts and labor. The Contractor shall maintain internal records of the warranty program, which shall be available for review by Government personnel. The Contractor shall pass through to the Government any supplier warranties acquired by the Contractor as a result of work performed under this contract.

7.0 Appendix

· Engine Life Limited Components (LLC) document Comment by Jackson, Lisa A. (DFRC-A): Where is this document?