PWS_Attach_B.pdf

T56 PWS - ATTACHMENT B

Initial Production Evaluation of Critical and Sensitive Repair Procedures Revision 29 Oct 24

1. The following identifies the engineering defined critical and sensitive repair procedures for repair of the T56-A-15 and T56-A-15A engine and its components. Substantiation of the repair procedures is based upon the sensitivity of the repairs. The sensitivity of the repair procedures is dependent upon the difficulty and criticality of the repairs, the specific application, as well as the Contractor’s required degree of familiarity with the particular repairs, equipment and facilities.

The sensitivity of the repairs is described as sensitive or critical. All repairs listed as sensitive or critical can result in reduced component/assembly service life or premature failure in event that a substandard or inadequate repair or product is provided.

2. For critical and sensitive repairs, the Contractor is required to complete an Initial Production Evaluation (IPE) on components or assemblies and obtain Government cognizant engineering authority (CEA) approval of the substantiation of the repair procedure. The minimum levels of substantiation required for the specific repair procedures are based on the repair procedure, the facilities and support equipment to be used and Contractor’s personnel experience with the specific repairs. Table 1 is provided to assist in identifying the Level of substantiation required for each identified critical and sensitive repair procedure, based upon the repair procedure’s sensitivity and the Contractor’s facilities, equipment, and personnel at the site where the repair procedure will be performed.

3. The Government’s (CEA), or an agent on their behalf, will perform a documentation or physical review of the Contractor IPE for critical and sensitive repairs as described below. When a sensitive or critical procedure is reviewed and substantiated by the cognizant Government engineering authority (whether by documentation or physical review), the Contractor shall be responsible for maintaining the repair procedure as a fixed process, and establish “process orders”, work instructions, or operating procedures to describe all necessary significant repair processes in detail and identify all significant parameters. Significant repair processes are defined as any repair processes capable of altering component material or mechanical properties or component function. Reference the listing of applicable significant repair processes identified in Table 3 of this Appendix. The process orders, or equivalent, shall be complete and contain sufficient information to allow the Contractor to repeatedly produce satisfactory products. These process orders, or equivalent, shall be supplied to the responsible Government engineering office.

4. The following levels of substantiation identify the minimum requirements for Contractor IPE.

The Contractor is responsible for providing all the required documentation for Government cognizant engineering review and approval:

TABLE 1: REPAIR SUBSTANTIATION LEVELS – T56 ENGINE/COMPONENTS

Sensitive Repair

Critical Repair

Level I Level II

Level I – For each critical and sensitive repair procedures in TABLE 2, the Contractor shall prepare an IPE Substantiation Package containing a summary list for each of the following: a) TO Required Support and Test Equipment with conformances, deviations, and alternates identified; b) TO Required Consumables with conformances, deviations, and alternates identified; c) All individual TO Inspections, Repairs, and Tests in the applicable TO Work Package(s) with procedures completed on the IPE article identified; d) All applicable Significant Repair Processes in TABLE 3 and identification of the Process Order or equivalent.

The Contractor shall also provide with each IPE Substantiation Package documentation outlining the Contractor’s current repair procedure for an item, documentation that consumables, support and test equipment meet T.O. requirements (or any proposed deviations), submittal of proposed repair process/routing sheets for the general repair procedures and processes to encompass all required TO inspections and repairs, and a completed repair process/routing sheet for the IPE part. Process Orders or equivalent, as described above, shall be required for the various significant repair processes in TABLE 3 and shall address the various components repaired using the procedures. Results of applicable laboratory reviews and repair IPE article inspection/test results shall be provided for engineering review. Deviations to TO required support equipment or consumables must be authorized by AFMC Form 202 which may be submitted concurrent with the IPE documentation.

Level II - Substantiation includes the requirements of Level I, as well as on-site physical review by the Government cognizant engineer of the entire repair procedure including preparation and all applicable inspections. Review may include evaluation of equipment, facilities, process sheets and “process controls” to be utilized, and the repair procedure.

5. After initial approval of the IPE items by the cognizant engineering authority, the contractor will be responsible for maintaining the critical and sensitive repair fixed processes under change control and providing repair process updates with supporting documentation to the cognizant engineering authority for approval:

a. Changes to significant processes which are capable of altering component material or mechanical properties or component function, require approval by the Government cognizant engineering authority. Reference the listing of applicable significant repair processes identified in this Appendix.

i. Process Order changes shall be provided to the Government cognizant engineering authority, with substantiating laboratory reports documenting their acceptable results.

b. Changes to TO required support equipment or consumables that are not otherwise authorized by an AFMC Form 202 or applicable Technical Order, require approval by the Government cognizant engineering authority.

c. Changes to the repair location where critical or sensitive repairs are performed shall require an IPE or update to the existing IPE documentation when the repair location change is made within the currently approved vendor facility CAGE Code location.

This requirement is not applicable for location changes within the same vendor facility when the repair process is to be performed using the same type or equipment (make/model), or similar equipment with equal or improved process capability.

d. Changes to the repair location where critical or sensitive repairs are performed shall require a repair qualification request to be submitted in accordance with Appendix A- PWS Section 1.5.3 when the location change is from a currently approved vendor facility CAGE code location to a USAF unapproved CAGE code location. The repair qualification request may be submitted as a new repair source qualification request, or as an update to the approved sub vendors in the original repair source qualification if applicable.

6. Critical and Sensitive Repair Procedures identified in the following Table 2 require substantiation in accordance with the requirements for the specified Repair Level. IPE’s shall be performed during repair of first production items inducted for repair by the contractor. The Government shall provide the components, modules, and assemblies identified in Table 2 for the IPE of the repair procedures. If the Contractor is currently in production of significant quantities of the same or similar component using the TO 2J-T56-53 for another customer, the cognizant Government engineer may authorize substantiation documentation to be submitted substituting the other customer parts for IPE articles, or may waive IPE requirements.

TABLE 2: T56-A-15/T56-A-15A CRITICAL AND SENSITIVE REPAIR PROCEDURES

No. Repair Procedure

T.O.

2J-T56-53

Work Package

Sensitivity

Initial Production Evaluation

Part Application

P/N* NSN*

Group 1: General Process Repair Substantiation with No Initial Production Evaluation Required

1 Component cleaning Multiple Sensitive General N/A N/A

2 Bearing inspection

WP 012, 040,

044, 066, 140, Sensitive General N/A N/A

Group 2a: T56-A-15 Module Initial Production Evaluation

3 Inspect and repair the compressor case WP 138 00 Sensitive

Compressor Module 23072502 2840-01-487-1830

Inspect and repair the compressor front stator Labyrinth seal

WP 139 00 Sensitive

Inspect and repair the compressor air inlet housing assembly

WP 134 Sensitive

6 Inspect and repair the extension shaft housing WP 131 Sensitive

7 Inspect and repair the compressor vane assemblies WP 138 00 Sensitive

8 Inspect and repair the compressor diffuser case WP 155 00 Sensitive

Inspect and repair the accessory drive housing, cover, gears, and gearbox assembly

WP 124, 125,

126, 127 Sensitive

10 Inspect, repair, and test the fuel nozzles WP 246 00 Sensitive

Inspect, repair, and test the main pressure and scavenge, external scavenge oil pump, and filters

WP 257, 259,

260 Sensitive

Inspect, repair, and test power section wiring harness assemblies, RH and LH

WP 261 00 Sensitive

13 Inspect, repair, and test the anti-icing air valve WP 270 00 Sensitive

14 Inspect, repair, and test the anti-icing solenoid valve

6J15-10-64- 13 Sensitive

Inspect and repair the compressor tie bolt, wheels, and blades, and compressor wheel and blade assembly and static balance

WP 145, 147

16 Compressor rotor assembly and balance WP 147 00 Critical

17 Compressor module assembly WP 158, 159 Critical

18 Inspect and repair the turbine inlet casing WP 205 00 Sensitive

Turbine Module 23078542 2840-01-337-2608

19 Inspect and repair the turbine front bearing cage WP 204 00 Sensitive

20 Inspect and repair the turbine front bearing support WP 204 00 Sensitive

21 Inspect and repair the turbine rear bearing seal assemblies WP 212 00 Sensitive

22 Inspect and repair the turbine guide vane and seal support WP 206 00 Sensitive

23 Inspect and repair the turbine vane segment assemblies WP 207 00 Sensitive

24 Inspect and repair the turbine vane casing WP 207 00 Sensitive

25 Inspect and repair the turbine rear bearing support assembly WP 185 00 Sensitive

26 Inspect and test the turbine thermocouples WP 263 00 Sensitive

Inspect, repair, and test the thermocouple harness assemblies, RH and LH

WP 264 00 Sensitive

Inspect and repair turbine rotor wheels, spacers, blades and clamp bolts

WP 208 00 Sensitive

29 Turbine rotor assembly, grind, and balance WP 214 00 Critical

30 Turbine module assembly WP 214 00 Sensitive

31 Inspect and repair the reduction gear front housing WP 012, 048 Sensitive

RGB

Assembly

23073709, 23080237 2840-01-492-9017

32 Inspect and repair the reduction gear rear housing WP 012, 035 Sensitive

33 Inspect and repair the main and inner diaphragms WP 012, 041 Sensitive

34 Inspect and repair the main drive gear WP 040 00 Sensitive

35 Inspect and repair the planet gear assembly WP 042 00 Sensitive

36 Inspect and repair the pinion shaftgear WP 040 00 Sensitive

37 Inspect and repair the planet rear carrier assy WP 042 00 Sensitive

38 Inspect and repair the propeller shaft WP 042 00 Sensitive

39 Inspect and repair the propeller brake WP 031 00 Sensitive

40 Reduction gearbox assembly WP 049, 050, 051 Critical

41 Reduction gearbox testing WP 052, 053 Critical

Inspect, repair, and test the torquemeter and safety coupling assembly

WP 059, 065,

067, 071, 072, Critical Torquemeter 6897603 2840-01-111-4765

Group 2b: Miscellaneous Component Initial Production Evaluations

43 Inspect and repair the combustion inner casing WP 197 00 Sensitive

Casing Combustion

Chamber Inner 6789860 2840-00-629-9195

44 Inspect and repair the combustion inner casing liner WP 197 00 Sensitive

Combustion Chamber Inner Casing Liner

6789748 2840-00-632-8150

45 Inspect and repair the combustion liner WP 196 00 Sensitive Combustion

Liner 6894068 2840-01-049-1153

Inspect, repair, and test the temperature datum control amplifier

5E3-15-3 Sensitive T.D. Amplifier 23059687 5996-01-406-4035

47 Inspect and repair the turbine-to-compressor tie bolt WP 167 00 Sensitive

Turbine to Compressor

Tie Bolt 6844778 2840-00-014-1748

48 Inspect and repair the turbine coupling shaft WP 173 00 Sensitive Turbine

Coupling Shaft 6846907 2840-00-012-7100

49 Inspect and repair the combustion outer casing WP 196 00 Sensitive Case

Combustion 6842689 2840-00-012-7130

Chamber Outer

Inspect, repair, and test the special purpose thermocouple lead assembly (Y-lead)

WP 264 00 Sensitive

Cable Assembly - Electrical, Turbine

Thermocouple (Y-Lead)

6847718 6150-00-756-5794

Inspect, repair, and test the TD Valve to Amplifier cable assemblies

WP 276 00 Sensitive

Cable Assembly - TD Valve to

Amplifier

6805799 6150-00-725-4952

Inspect, repair, and test the fuel control, including the electro mechanical rotor actuator

6J3-4-24-13 Sensitive Fuel Control

23067638, 23064874, 440970-3, 440970-4

2915-01-444-7667

Inspect, repair, and test the temperature datum valve including the motor generator

6J15-3-87-3 Sensitive Temperature Datum Valve

Assembly

23030485, 330332-5 2915-01-318-8927

54 Inspect, repair, and test fuel pump 6J10-4-27-3 Sensitive Fuel Pump

Assembly

6827283, 022489-054-

4320-00-654-3617

55 Inspect, repair, and test high pressure fuel filter WP 240 00 Sensitive

High Pressure Filter

Assembly 6821460 2915-00-859-2915

56 Inspect, repair, and test the ignition exciter 8E1-2-22-53 Sensitive Ignition

Exciter 6895689, 10-111160-6 2925-01-072-6709

57 Inspect, repair, and test the speed sensitive valve 6J7-7-3 Sensitive Speed Sense

Valve 6821493 2995-00-876-9685

58 Inspect, repair, and test the speed sensitive control 6J11-12-3 Sensitive Speed Sense

Control 6873465, 9901-300 2915-00-464-6946

59 Inspect, repair, and test the coordinator control WP 275 00 Sensitive

Coordinator Control

Assembly 6794215 2915-00-777-9017

Group 3: T56-A-15A Initial Production Evaluations

60 Inspect and repair the compressor case SWP 138 01 Sensitive Compressor

Module 23095676 2840-01-652-8921

61 Turbine rotor assembly, grind, and balance SWP 214 01 Critical

Turbine Module 23093468 2840-01-652-6038

62 Inspect and repair turbine vane segments SWP 207 01 Sensitive

Inspect and repair turbine rotor wheels, spacers, blades and clamp bolts

SWP 208 01 Sensitive

64 Inspect and repair turbine guide vane and seal support SWP 206 01 Sensitive

Group 4: Power Section/Engine Initial Production Evaluations

64 Power section assembly/module installation

WP 219, 220,

221, 222 Critical Power Section N/A N/A

65 Inspect, repair, and test low pressure fuel filter assy WP 241 00 Sensitive Power Section N/A N/A

66 Inspect, repair, and test the external scavenge oil filter assy WP 258 00 Sensitive Power Section N/A N/A

67 Power section testing WP 285 00 Critical Power Section N/A N/A

68 Engine power package buildup (in QEC kit) 16W14-12-3 Critical Engine in QEC N/A N/A

69 Engine power package testing (installed in QEC kit)

2J-T56-56

WP 058

1C-130B-2-

4CL-2

Critical Engine in QEC N/A N/A

*Note: P/N and NSN are reference only. Alternate items to those identified in TABLE 2 may be substituted for IPE as long as they are repaired using the same TO Work Package procedures.

TABLE 3: SIGNIFICANT REPAIR PROCESSES CAPABLE OF ALTERING

MATERIAL AND MECHANICAL PROPERTIES

The following examples are typical processes considered significant in that they are capable of producing alterations to material structures, mechanical properties, and ultimately, item reliability, if performed improperly, and cannot normally be evaluated without destructive testing.

1. Casting Processes

2. Forging Processes

3. Heat Treatment and Surface Hardening Processes

4. Grinding

5. Electrochemical Machining Processes (Cavity Sinking, Drilling, Grinding, etc.)

6. Chemical Milling

7. Electro-Discharge Machining

8. Laser Beam Metal Removal Processes

9. Electron Beam Processes

10. Peening Processes

11. Fusion Welding

12. Brazing

13. Soldering

14. Metal Electroplating Processes

15. Coating Processes including, but not limited to, the following:

a. Plasma Spray

b. Thermal Spray

c. Diffusion Coatings

d. Thermal Barrier Coatings

16. Surface Finishing Processes including, but not limited to, the following:

a. Honing

b. Sutton Barrel

17. Non-Destructive Inspections or Testing (NDI or NDT), including, but not limited to the following:

a. Fluorescent Penetrant

b. Eddy Current

c. Ultrasonic

d. Laser Holography

e. Magnetic Particle Inspection

f. Radiography

18. Water-jet Stripping