SPE4A219R0055 A0003 (issued 16Mar20).pdf

Offers must acknowledge receipt of this amendment prior to the hour and date specified in the solicitation or as amended, by one of the following methods:

(a) By completing items 8 and 15, and returning or (c) By separate letter or electronic communication which includes a reference to the solicitation and amendment numbers. FAILURE OF YOUR ACKNOWLEDGMENT TO BE RECEIVED AT THE PLACE DESIGNATED FOR THE RECEIPT OF OFFERS PRIOR TO THE HOUR AND DATE SPECIFIED MAY RESULT IN REJECTION OF YOUR OFFER. If by virtue of this amendment you desire to change an offer already submitted, such change may be made by letter or electronic communication, provided each letter or electronic communication makes reference to the solicitation and this amendment, and is received prior to the opening hour and date specified.

E. IMPORTANT: Contractor is not is required to sign this document and return copies to the issuing office.

AMENDMENT OF SOLICITATION/MODIFICATION OF CONTRACT 1. CONTRACT ID CODE

2. AMENDMENT/MODIFICATION NUMBER 3. EFFECTIVE DATE 4. REQUISITION/PURCHASE REQUISITION NUMBER 5. PROJECT NUMBER (If applicable)

7. ADMINISTERED BY (If other than Item 6) CODE

STANDARD FORM 30 (REV. 11/2016)

Prescribed by GSA FAR (48 CFR) 53.243

FACILITY CODE

9A. AMENDMENT OF SOLICITATION NUMBER

9B. DATED (SEE ITEM 11)

10A. MODIFICATION OF CONTRACT/ORDER NUMBER

10B. DATED (SEE ITEM 13)

11. THIS ITEM ONLY APPLIES TO AMENDMENTS OF SOLICITATIONS

The above numbered solicitation is amended as set forth in Item 14. The hour and date specified for receipt of Offers is extended. is not extended.

12. ACCOUNTING AND APPROPRIATION DATA (If required) copies of the amendment; (b) By acknowledging receipt of this amendment on each copy of the offer submitted;

13. THIS ITEM APPLIES ONLY TO MODIFICATIONS OF CONTRACTS/ORDERS.

IT MODIFIES THE CONTRACT/ORDER NUMBER AS DESCRIBED IN ITEM 14.

CHECK ONE A. THIS CHANGE ORDER IS ISSUED PURSUANT TO: (Specify authority) THE CHANGES SET FORTH IN ITEM 14 ARE MADE IN THE CONTRACT ORDER

NUMBER IN ITEM 10A.

B. THE ABOVE NUMBERED CONTRACT/ORDER IS MODIFIED TO REFLECT THE ADMINISTRATIVE CHANGES (such as changes in paying office, appropriation data, etc.) SET FORTH IN ITEM 14, PURSUANT TO THE AUTHORITY OF FAR 43.103(b).

C. THIS SUPPLEMENTAL AGREEMENT IS ENTERED INTO PURSUANT TO AUTHORITY OF:

D. OTHER (Specify type of modification and authority)

Except as provided herein, all terms and conditions of the document referenced in Item 9A or 10A, as heretofore changed, remains unchanged and in full force and effect.

15C. DATE SIGNED

15A. NAME AND TITLE OF SIGNER (Type or print)

16C. DATE SIGNED

16A. NAME AND TITLE OF CONTRACTING OFFICER (Type or print)

14. DESCRIPTION OF AMENDMENT/MODIFICATION (Organized by UCF section headings, including solicitation/contract subject matter where feasible.)

PAGE OF PAGES

6. ISSUED BY CODE

8. NAME AND ADDRESS OF CONTRACTOR (Number, street, county, State and ZIP Code) (X)

CODE

15B. CONTRACTOR/OFFEROR

(Signature of person authorized to sign)

16B. UNITED STATES OF AMERICA

(Signature of Contracting Officer)

Previous edition unusable

A0003

SPE4A2

DLA AVIATION RICHMOND

8000 JEFFERSON DAVID HIGHWAY

RICHMOND, VA 23297

INITIATOR: INGRID SMITH, INGRID.SMITH@DLA.MIL

F108 Workload Augmentation

SPE4A219R0055

1 18

03/16/2020

11/22/2019

CONTINUATION SHEET REFERENCE NO. OF DOCUMENT BEING CONTINUED

SPE4A2-19-R-0055 Amendment 0003

Page

NAME OF OFFEROR OR CONTRACTOR

50336-101 NSN 7540-01-152-8067

US GOVERNMENT PRINTING OFFICE 1990-262-081

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

Amendment 0003 is issued to clarify, change or add the subject RFP requirements, summarized as follows:

• Extends the proposal due date at Section 9 of the RFP SF-33 and as amended at A0002

Section B

• Replaced in its entirety due to a change in the Government’s Contract Line Item Number (CLIN) structure

Section C

• Replaces and/or clarifies the following requirements within the Statement of Work

(SOW)

o C.1.2.2.6 o C.1.2.5.11 o C.1.2.10 o C.1.2.16 o C.2.1 o C.2.2 o C.5.0

Section J

• Adds Appendix F to the “List of Attachments”

Section L

• Replaces L.10 and its subparts in their entirety due to the CLIN restructure outlined herein

Section M

• Replaces M.5 and M.6 and their subparts in their entirety due to the CLIN restructure outlined herein

Appendix B

• Replaces the NOTE

• Removes the following Technical Orders from the requirement as no longer applicable or included in error at RFP:

o 2--1--11 Corrosion Control of Engine Parts During Overhaul

• Adds the following TOs to the requirement that were omitted in error at time of RFP issuance:

o 1-1-691 Corrosion Control of Engine Parts During Overhaul

Appendix E

• Replaces Appendix E to clarify and ensure no conflicts with SOW requirements

Appendix F

• Adds the forms for Contractor input and submission to USAF; USAF will load data to Comprehensive Engine Management System (CEMS)

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

The aforementioned RFP section paragraphs and Appendices B, E and F are replaced or added as shown on pages 4 – 18 herein.

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

Block 9 of the RFP SF-33 is hereby amended to reflect an extended proposal response date, FROM: 1500 local time 4/10/2020 TO: 1500 local time 5/1/2020.

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

Section B

B.1 Offerors shall submit proposed pricing for each year of the contract term that includes all elements of the F108-100 to F108-100A remanufacture requirements as set forth in this solicitation. Prices shall be proposed on a remanufactured F108 engine unit price basis via Contract Line Item Number (CLIN) 0001. The Best Estimated Quantity (BEQ) identified in the table below is for the total five-year contract requirement, with an estimate of up to thirty (30) engines delivered to the Contractor for overhaul each year.

B.1.1 Due to the variability in replacement for an engine received for overhaul, Life Limited Parts (LLP) are established as sub-CLINs, and thus, subject to invoice only when the applicable LLP has been replaced on the Contractor overhauled engine. The Government has not identified a BEQ for the LLP sub-CLINs, however, the USAF has supplied scrap/condemnation rate data (eight-quarter look) as a data point for use in calculating proposed sub-CLIN unit prices.

Contract Line Item Number (CLIN) or

Sub-CLIN Item Name NSN PN BEQ Proposed U/P

CLIN 0001 Overhaul of F108-100 to F108-100A 2840F108CF100PN 9995M60G01 150 Sub-CLIN 0001AA Fan Disk 2840011832046 305-048-821-0 Sub-CLIN 0001AB Booster Spool 2840011878164 305-026-618-0 Sub-CLIN 0001AC Fan Shaft 2840011873189 301-579-120-0 Sub-CLIN 0001AD Front Shaft (HPC) 2840011873192 1275M37P02 Sub-CLIN 0001AE Stage 1-2 Spool (HPC) 2840013513400 2411M21G01 Sub-CLIN 0001AF Stage 3 Disk (HPC) 2840011873182 2116M23P01 Sub-CLIN 0001AG Stage 4-9 Spool (HPC) 2840012193703 1588M89G03 Sub-CLIN 0001AH Compressor Rear (CDP) Air Seal 2840012403416 1319M25P02 Sub-CLIN 0001AI Front Shaft (HPT) 2840012346142 1282M71P01 Sub-CLIN 0001AJ Front Air Seal (HPT) 2840012349105 1282M72P07 Sub-CLIN 0001AK Disk (HPT) 2840012780759 1475M29P02 Sub-CLIN 0001AL Rear Shaft (HPT) 2840015186769 1864M91P02 Sub-CLIN 0001AM Stg 1 Disk 2840011856489 301-331-126-0 Sub-CLIN 0001AN Stg 2 Disk 2840011856490 301-331-227-0 Sub-CLIN 0001AO Stg 3 Disk 2840011856491 301-331-322-0 Sub-CLIN 0001AP Stg 4 Disk 2840011856492 301-331-427-0 Sub-CLIN 0001AQ LPT Rotor (Conical) Support 2840011856424 305-056-115-0 Sub-CLIN 0001AR LPT Shaft 2840011873190 301-330-060-0 Sub-CLIN 0001AS LPT Stub Shaft 2840011873191 301-330-626-0

B.2 If out-year pricing is not proposed by unit price, the offeror shall include the applicable proposed escalation for each CLIN and/or sub-CLIN, labeled as such in the offeror’s worksheet, along with the basis for such escalation.

B.3 While the Government acknowledges the FAR Part 12 nature of the acquisition, offerors shall provide unit price build up details for CLIN 0001 and all sub-CLINs to ensure a fair and reasonable price determination can be made. This build up may include, but is not limited to: (1) the offeror’s bill of materials for the Quick Engine Change (QEC) kit and all parts identified for replacement within the SOW at Section C

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

and attached technical data (e.g., TC/TOs, Service Bulletins, etc.) and (2) costs for remanufacture labor, testing, etc., or service fee.

B.4 Over and Above (O&A) may apply during contract performance. As described at C.2.2 below, O&A may apply due to unanticipated maintenance costs discovered during the overhaul process of an engine. O&A includes maintenance and/or material replacements not identified within the SOW and associated technical data at time of proposal and contract award.

B.4.1 The Contractor shall advise the DLA POC and USAF Engineering of all unanticipated maintenance costs for disposition and pricing requirements for evaluation against CLIN 0002 under the contract.

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

Section C

C.1.2.2.6 Line Replaceable Units (LRUs) shall be removed and overhauled as required to return engine to serviceable status. Shop Replaceable Units (SRUs) as shown in Workscope Planning Guide shall be removed and torn down to piece part to be overhauled and returned to serviceable condition. (List of authorized SRUs is in section C.1.2.4.1). SRU Module 4, Fan Frame Assy, shall be inspected per the WPG. Modules 16 and 17, AGB and TGB, require a flow-check with disassembly to piece part and overhaul required only if asset fails flow-check.

C.1.2.5.11 All engines that have thermal spray coated Aft Stator Case shall have the Aft Stator cases replaced with the New Linerless Cases assembly 9995M25G05 and marked with an L after the part number for tracking purposes using a vibropeen etcher. See Build Policy Table for authorized module part numbers for installation. Parts shall be marked IAW the ESM Standard Practice Manual. The base case PN 1559M70G02 is the only acceptable case at this time.

Repairs of the case with thermal spray are not authorized.

C.1.2.10 Parts Manufacturing Approval (PMA): PMA will not be considered for use with this contract. If a PMA part is discovered during maintenance, contact the AFLCMC/LPE Cognizant Engineering Authority for guidance.

C.1.2.16 Reporting: The contractor shall provide completed Certificate of Conformance documentation with each F108/CFM56-2B engine assembly and its component parts that have been overhauled with the intent of returning these assemblies or component parts to service.

This documentation shall have part number, serial number, work accomplished, Service Bulletins complied with, on serviceable tag, DD Form 1574. The contractor shall ensure that all reporting as specified under the following Contract Data Requirements is accomplished:

A001: AFMC Form 413 (Depot Maintenance Production Report) A002: Commercial Asset Visibility Air Force (CAVAF) Reporting, formerly CAVII A003: Comprehensive Engine Management System (CEMS) Reporting

Data in accordance with the AFMC Form 413 report shall not be waived, although contractor’s format with all the same data elements as the AFMC Form 413 report may be accepted, if approved through the PCO. For CAVAF reporting, the contractor shall input the data IAW the Appendix B and CAVAF guide. Each Serial Number Engine and Module Component assembly is loaded into Comprehensive Engine Management System (CEMS) and all part number changes and TCTO accomplishment through major overhaul must be documented. CEMS data inputs shall be pushed to the USAF following the provided formatting instructions in Appendix F.

The applicable form(s) shall be emailed to cems.pmo.helpdesk@us.af.mil. The CEMS Helpdesk may be reached at 1-800-956-7351. In addition, the contractor shall submit Supply Discrepancy Reports (SDRs) when required IAW the contract’s Appendix B, “End Item and Government Furnished Equipment Management,” Section 7. Contractor shall process Deficiency Reports when required IAW Section C.1.2.12 of this SOW. AFMC Form 413 Depot Maintenance Production Reporting, CAVAF Reporting, Mishap Reporting, and Deficiency Reporting shall be on-time, correct, and complete.

mailto:cems.pmo.helpdesk@us.af.mil

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

C.2.1 Kits

A complete C-PUP (CFM Propulsion Upgrade) kit will be provided to the Contractor by the USAF for each engine. The kit will be shipped by the USAF to the Contractor’ maintenance facility prior to induction. It is incumbent upon the Contractor to accurately provide kit demand to the USAF in anticipation of maintenance production capability so that kits are in place prior to each engine’s induction.

The Contractor shall include the kit ship-to address and SRAN/DODAAC in their proposal.

Quick Engine Change (QEC) kits will be provide by the Contractor “with each completed engine” and included in the Contractor’s quoted price for F108 whole engine price. Reference T.O.

1C135(K)R-10 QEC Kit. In the event the Contractor receives an incomplete QEC kit for overhaul, the Contractor shall submit a Supply Discrepancy Report (SDR) for review by the Government. CLIN 0002 may apply.

C.2.2 Unanticipated Maintenance and Parts Over and Above

Unanticipated maintenance consists of maintenance required for engine issues discovered during the typical overhaul and upgrade of the engine from the F108-100 to the F108-100A.

Over and above does not apply to parts contained in the Government-provided C-PUP kits or identified in this SOW for contractor sourcing and specified at technical data (e.g., TC/TOs, Service Bulletins, etc.) incorporated herein. Over and above will apply to additional Service Bulletins identified at the Workscope Planning Group meeting that are not called out in this

SOW.

All unanticipated maintenance and required parts identified for the engine shall be brought to the attention of Cognizant Engineering Authority and contracting officer for disposition. The Contractor shall adhere to clause 252.217-7028 and will bill unanticipated maintenance and parts over and above against CLIN 0002.

All installed parts must be capable of meeting the designed functional capabilities as specified in applicable ESM prior to installation.

During work on an engine if an obvious defect is discovered in an area that is not related to the problem driving removal of the engine, then the defect shall be brought to the attention of Cognizant Engineering Authority and contracting officer for disposition. The Contractor shall follow CFR 252.217-7028 if beyond the work scope of this contract is required.

C.5.0 CEMS Access and Training

The Contractor is required to have access to CEMS which also requires a government issued Common Access Card (CAC). Additionally, the Contractor is required to provide CAC readers for use with their computers. The Government will coordinate issuance of CAC cards to Contractor personnel. Access to CEMS will not be authorized for Foreign Nationals.

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

SECTION J

LIST OF ATTACHMENTS

Appendix A – List of Acronyms Appendix B – Applicable Technical Orders Appendix C – Workscope Planning Guide Appendix D – Gearbox Airflow Check Appendix E – Low Pressure Turbine Appendix F – CEMS Input Forms

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

Section L

L.10 Volume 3 – Price Proposal

L.10.1 Offerors shall provide a price proposal utilizing (unlocked) Microsoft Excel worksheets.

The price proposal must be submitted on a separate compact disc (CD) at the time of proposal submission. The CD must be labeled with the solicitation number, offeror’s name, date of submission and the proposal volume.

L.10.2 The offeror’s price proposal shall consist of:

(1) A total unit price for the remanufacture of the F108 whole engine from the F108-100 to the F108-100A via CLIN 0001 as established at Section B herein for a one-year base period and four, one-year option periods. If out-year pricing is not proposed, the offeror shall include its applicable, proposed annual escalation, labeled as such in the offeror’s worksheet

(2) Unit prices for replacement of LLPs via sub-CLINs 0001AA-AS as established at Section B herein for a one-year base period and four, one-year option periods. If out-year pricing is not proposed, the offeror shall include its applicable, proposed annual escalation, labeled as such in the offeror’s worksheet.

(2) Unit price build up details for CLIN 0001 and all sub-CLINs to include (a) the offeror’s bill of materials for the QEC and all parts identified for replacement within the SOW and attached technical data (e.g., TC/TOs, Service Bulletins, etc.) and (b) service fee, and

(3) Proposed delivery days

L.10.3 The government reserves the right to request additional supporting price data (i.e., data other than certified cost or price data) in accordance with FAR 15.403-3, if needed, in order to evaluate price proposals and ultimately, arrive at a fair and reasonable price determination.

L.10.4 The price proposal shall contain the offeror’s executed clauses and provisions and the information at L.7. These requirements are not subject to the page limitations specified for the price proposal.

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

Section M

M.5 Price Evaluation Factor

M.5.1 Price will be evaluated based on a single, total evaluated price (TEP) calculated through the expected five-year life of the contract. The TEP will be calculated based on a five-year average unit price for CLIN 0001 and all sub-CLINs multiplied by the BEQ (for CLIN 0001) and the Government’s figure for LLP (sub-CLINs 0001AA-0001AS) replacement calculated based on USAF eight-quarter scrap/condemnation data. The table and narrative below provides an elementary example of the TEP calculation, using nominal pricing figures.

CLIN / Sub-CLIN Proposed U/P Year 1

Proposed U/P Year 2

Proposed U/P Year 3

Proposed U/P Year 4

Proposed U/P Year 5 Average U/P BEQ / Govt est for TEP TEP

CLIN 0001 $1,500,000 $1,522,500 $1,545,338 $1,568,518 $1,592,045 $1,545,680 150 $231,852,011.65 Sub-CLIN 0001AA $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 17 $437,942.69 Sub-CLIN 0001AB $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 6 $154,568.01 Sub-CLIN 0001AC $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 6 $154,568.01 Sub-CLIN 0001AD $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 3 $77,284.00 Sub-CLIN 0001AE $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 96 $2,473,088.12 Sub-CLIN 0001AF $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 11 $283,374.68 Sub-CLIN 0001AG $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 6 $154,568.01 Sub-CLIN 0001AH $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 3 $77,284.00 Sub-CLIN 0001AI $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 32 $824,362.71 Sub-CLIN 0001AJ $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 27 $695,556.03 Sub-CLIN 0001AK $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 62 $1,597,202.75 Sub-CLIN 0001AL $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 9 $231,852.01 Sub-CLIN 0001AM $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 2 $51,522.67 Sub-CLIN 0001AN $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 2 $51,522.67 Sub-CLIN 0001AO $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 2 $51,522.67 Sub-CLIN 0001AP $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 2 $51,522.67 Sub-CLIN 0001AQ $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 2 $51,522.67 Sub-CLIN 0001AR $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 2 $51,522.67 Sub-CLIN 0001AS $25,000 $25,375 $25,756 $26,142 $26,534 $25,761 2 $51,522.67

Total TEP $239,374,321.36

The proposed unit prices for each CLIN/sub-CLIN are averaged to arrive at a five-year average unit price. The average unit price per line item is multiplied by the applicable BEQ / Government estimate figure for a line item TEP. The line item TEPs are summed to arrive at the Total TEP as shown above.

M.5.2 The TEP will not be contractually binding, however, all proposed rates and associated Production Lead Times (PLT) that comprise the TEP will be binding.

M.5.3 Proposed pricing shall be evaluated for price reasonableness. Price reasonableness is a judgment of the proposed price as compared to competitive prices received, current market conditions, appropriate industry indices and other relevant measures. Competitiveness is not determined by simply comparing the prices proposed by other offered prices but involves making trade-off comparisons between cost and non-price factors. Prior price history will be reviewed when determining prices fair and reasonable. If an offered price cannot be determined reasonable using measures referenced above, the Government may ask for data other than cost or pricing data described at FAR 15.4 to substantiate the offered pricing.

M.5.4 Prices shall be evaluated for unbalanced pricing in accordance with FAR 15.404-1(g).

Unbalanced pricing exists when, despite an acceptable TEP, the price of one or more component items of function of the remanufacturing effort is significantly overstated or understated as indicated by the application of price analysis techniques. The government shall analyze offers to determine whether unbalanced separately priced line items exist.

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

M.6 Split Award Decision

M.6.1 Separate from best value trade-off evaluation and decision outlined herein is the possibility of a split award decision to be made at the discretion of the Government.

M.6.2 Provided offerors within the competitive range are deemed acceptable within the non-price evaluation factors, and pricing is deemed competitive, the Government may elect to split the total requirement among offerors if that decision is in the best interest of the Government.

M.6.3 Should a split award result, the Government reserves the right to adjust the engine remanufacture quantity split via contract modification prior to the beginning of each performance period based on contractor performance and capacity constraints, if any.

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

Appendix B

Applicable Technical Orders

NOTE

Basic T.O. dates in this APPENDIX are current as of the date of this SOW and in accordance with all Amendments. The SOR at the facility where work under provision of this specification is accomplished shall control and maintain all technical orders and other technical directives, manuals and associated documents applicable to the work requirements, in an updated and current status. For any AF specific TO called out in the SOW, the corresponding ESM/CMM is authorized. The SOR shall accomplish a timely review of revisions and directives applicable to the work requirements for this specification. The review shall consider the impact on work requirements, cost, schedules and any other pertinent factors. Written evaluation, along with specific back-up data for those changes which impact the performance of the specification shall be provided to PCO within ten working days after receipt. The SOR shall incorporate all authorized technical orders and subsequently negotiate impact on cost or schedules with PCO.

NUMBER SECTIONS/CHAPTERS/PAGE TITLE

00-5-1 15-Feb-19 Air Force T.O. System 00-5-3 15-Feb-19 T.O. Distribution System 00-5-15 29-Sep-17 TCTO Process 00-20-1 1-Jun-18 Preventative Maintenance Program 00-20-2 15-Mar-16 Maintenance Data Collection 00-20-3 10-Jul-17 Maintenance Procedures of Reparable Property

00-25-113 15-Dec-16 Conservation and Segregation of Critical Alloy and Precious Metal Bearing Parts and Scrap

00-25-113-F108 15-Dec-16 Critical Material Parts 00-25-195 1-Oct-12 Source, Maint, and Recover Coding 00-25-254-1 15-Aug-18 D042 User Manual CEMS 00-25-257 15-Oct-07 Engine Trending and Diagnostics User's Manual

00-25-257-7-CD-

1 15-Apr-16

Engine Trending and Analysis User's Manual for Turbofan Engine Model F108-100/201

00-35D-54 1-Sep-15 Deficiency Reporting 00-85-20 1-Feb-18 Engine Shipping Inst 1C-135(K)R-1-1 30-May-85 Flight Manual 1C-135(K)R-10 1-Jul-17 Buildup Instruction Aircraft Power Package 1C-135-6 15-Jun-15 Aircraft Maintenance Work Unit Code Manual 1-1-691 31-Oct-84 Corrosion Control of Engine Parts During Overhaul 2--1--16 30-Aug-03 Reident by S/N of Acft Engines 2J-1-13 15-Jun-30 Cleaning of Gas Turb Acft Engs & Parts

2J-1-18 15-Oct-18 Preparation for Shipment and Storage of Gas Turbine Engs

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

2J-1-19 1-Jul-03 Insp& Disposition of Gas Turb Eng After Accident or Engine Dropped During Handling

2J-1-24 15-Jan-18 Comprising Complete Basic Gas Turbine Engine

2J-1-F108 15-Dec-16 Warranty Implementation Manual TurboFan Engine F108-CF-100

2J-F108-05-11 24-May-94 F108CF100 Engine Life Limits 2J-F108-1 1-Jan-17 Specific Operating Instructions 2J-F108-2-1 15-Oct-18 Maintenance Manual 2J-F108-2-2 1-Feb-19 Standard Practices Manual 2J-F108-2-3 1-Jan-17 Consumable Products Manual 2J-F108-13-1 1-Jan-17 Engine Shop Manual 2J-F108-13-2 1-Jan-17 Service Bulletin List 2J-F108-13-2-1 1-Jan-17 Service Bulletin, Depot 2J-F108-13-05-11 1-Jan-17 Engine Time Limits 2J-F108-13-72-00 1-Apr-18 Engine Assembly 2J-F108-13-72-09 1-Jan-17 General Procedures 2J-F108-13-72-21 1-Feb-17 Fan and Booster Assembly 2J-F108-13-72-22 1-Mar-18 Number 1 and 2 Bearing 2J-F108-13-72-23 1-Apr-18 Fan Frame Assembly 2J-F108-13-72-31 1-May-19 Compressor Rotor Assembly 2J-F108-13-72-32 1-Aug-18 Compressor Front Stator Assembly 2J-F108-13-72-33 1-Jan-17 Compressor Rear Stator Assembly 2J-F108-13-72-41 15-Aug-18 Combustion Case Assembly 2J-F108-13-72-42 1-Jan-17 Combustion Chamber 2J-F108-13-72-51 1-Jan-17 High Pressure Turbine Assembly 2J-F108-13-72-52 1-Jan-17 High Pressure Turbine Rotor Assembly

2J-F108-13-72-53 15-Mar-17 High Pressure Turbine Shroud and Stage one Low Pressure Turbine Nozzle Assy

2J-F108-13-72-54 1-Jan-17 Low Pressure Turbine Rotor 2J-F108-13-72-55 1-Jan-17 Low Pressure Turbine Shaft Assembly 2J-F108-13-72-56 1-Jan-17 Turbine Frame Assembly 2J-F108-13-72-61 1-Jan-17 Inlet Gearbox and No. 3 Bearing Assembly 2J-F108-13-72-62 1-Jan-17 Transfer Gearbox Assembly 2F-F108-13-72- 63 1-Jan-17 Accessory Gearbox Assembly 2J-F108-14 15-Nov-18 Illustrated Parts Catalog 2J-F108-19 1-Jan-17 Non-Destructive Test Manual 2J-F108-534 15-Sep-93 Modification of Combustor Assembly

2J-F108-537 27-Oct-99 Removal of Stage One Compressor Blades which Experienced Operational Instability

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

2J-F108-539C 15-Apr-20

Recalibration of IGV Rigging - 3 Degree Closure (Note: Supplement 539E changed this TCTO to a depot level TCTO)

2J-F108-540 8-Mar-93 No. 3 Bearing Improvement Program 2J-F108-550 1-Oct-97 Inspection of Fan Disk

2J-F108-552 1-Oct-97 Immersion Ultra-Sonic/Eddy Current Inspection of Fan Disk

2J-F108-554 1-Jun-98 Replacement of Combustion Chamber Assemblies with Small Tip Fuel Nozzles and Swirlers

2J-F108-567E 1-Jul-15 Inspection of Variable Bleed Valve Actuators for F108-CF-100 Series Engines

2JA3-63-4 15-Aug-18 Engine Starter 36E153-6E 2JA11-5-3-WA-1 15-Oct-14 Alternator Electrical Lead Assembly 2JA11-6-3-WA-1 15-Oct-14 T495 Wiring Harness 2JA11-7-3-WA-1 15-Oct-14 Control Parameter Wiring Harness 2JA12-12-13 1-Dec-04 Turbine Clearance Control Valve 5E6-3-116-3-1 15 Feb 16 (Section 1-10008) CIT Sensor

5E6-3-124-2-WA-

1 15-Oct-14

Component Maint Manual, T12 Temperature Sensor P/N 154BY (301-771-601-0) 73-21-41

5E6-3-125-2-WA-

1 15-Oct-14

Component Maint Manual, T12 Temperature Sensor P/N RP211-00 (301-798-601-0) (CFMI-TP-

CM 421)

6J3-4-113-3-WA-

1 15 Nov 16 (Section 1-8) Main Engine Control

6J3-4-113-4-WA-

1 1-Jan-17 Main Engine Control, IPB

6J3-8-20-23-WA-

1 1-Aug-16 Bleed Valve Fuel Gear Motor 6J8-37-13 01 Apr 18 (Section 1-10058) Fuel Nozzle (Parker) 6J8-47-3 1-May-18 Fuel Nozzle (Woodward FST) 6J10-4-89-13 1-Dec-16 Fuel Pump 6J15-20-5-13 30-Nov-96 Bleed Valve Stop Mechanism 6J24-10-13 1-Aug-18 Servo-Fuel Heater 7J1-85-13 31-Aug-86 Oil/Fuel Heat Exchanger 7J4-2-59-13 28-Feb-81 Lubrication Unit 7J10-21-13 30-Sep-16 Oil Tank 7J11-3-3 29-Feb-96 Oil Indicator Cap 8A6-2-8-3-WA-1 01 Jun 18 (Section 1-16002) Permanent Magnet Alternator 8D21-6-13-WA-1 1-Jun-18 N1 Speed Sensor 8D21-10-3 31 Oct 97 (Section 1-1004) No. 1 Bearing Vibe Sensor Endevco 8D21-11-3 01 Jun 09 (Section 1-1008) No. 1 Bearing Vibe Sensor Vibro-Meter

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

8E1-7-14-3 31 May 14 (Section 1-1006) Ignition Lead Assemblies 8E1-8-31-13 31 Jul 14 (Section 1-16002) Ignition Exciter, Unison 9H2-7-39-13 15 Jun 17 (Section 1-1006) Variable Stator Actuator 9H2-7-51-3 15-Jun-17 Ballscrew Actuator 16R1-2-27-3 10-Jun-05 Variable Stator Feedback Cable 16R1-2-33-3 30-Nov-87 Variable Bleed Valve Feedback Cable 33-1-37-1 15-Sep-14 Joint Oil Analysis Program Laboratory Manual 33-1-37-2 1-Jun-15 Joint Oil Analysis Program Laboratory Manual 33-1-37-3 30-Apr-18 Joint Oil Analysis Program Laboratory Manual 33-1-37-4 30-Aug-13 Joint Oil Analysis Program 33B-1-1 15-Oct-16 Nondestructive Inspection Methods 35D3-7-6-1 21-Nov-18 ETU-111/E Trailer, Aircraft Engine-Multi-Purpose 42E1-1-1 1-Dec-17 Aircraft Hose 42E2-1-2 15-Dec-02 Packing Gaskets

44B-1-15 28-Feb-92

Jet Engine Antifriction Bearing Handling, Removal, Cleaning, Inspection, and Installation at Jet Engine Base Maintenance Facilities

44B-1-102 1-Jun-17 Antifriction Bearings 44H3-1-3 15-Mar-12 Use of Boss, Cap & Tube Seals

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

Appendix E

Module 13/15 Inspection and Repair/Remanufacture

The Contractor shall restore the module to original life expectancy in compliance with all applicable CFM56-2B Engine Shop Manual (ESM) and Service Bulletin/Airworthiness Directive Requirements. The Contractor shall perform all inspections, replacement of parts, remanufacture, reassembly, adjustments, calibrations, USAF approved modifications, testing and operational checks, correct all discrepancies and malfunctions, and verify adequate and proper like new condition of any component, system, or subsystem. The Contractor shall remanufacture the Module 13/15 as follows:

Low Pressure Turbine (LPT) Rotor and Frame Assembly and component parts shall be remanufactured IAW the procedures outlined in the ESM 72-54-00 through 72-54-20 and 72-56- 00 through 72-56-10. This also includes Standard Practice Manual CFMI-TP-SP.2.

Contractor shall acquire all component parts from Air Force approved vendors, Government inventory, Original Equipment Manufacturer (OEM) approved vendors, or commercial inventories approved by the USAF and/or OEM. Life Limited Parts (LLP) shall be new and unused from Air Force approved sources or remanufactured from Government inventory. New and unused non-LLP components shall be from Air Force approved vendors, Government inventory, or OEM approved vendors. Non-LLP used serviceable commercial components shall be from used commercial inventories acquired originally from an Air Force or OEM approved vendors. The Contractor shall not acquire non-LLP used commercial parts from supplier sources that have been subject to any violation, penalty, or disciplinary actions leading to FAA disapproval of its aircraft, engine maintenance or operations. The Contractor shall provide FAA Form 8130-3 documentation for each used component in a module at time of module delivery.

The Contractor shall ensure all four stages of LPT blades are either brand new or fully restored to “as new” condition. Inspection serviceable limits are only sufficient if there is no corresponding repair attached to the inspection. “As new” condition is defined as blades that have had all remanufacture processes performed. All knife edges and Z-notches are restored to full remanufacture limits per Technical Order (T.O.) guidance. Blend repairs on the airfoils are allowed to restore to “as new” condition. All LPT blades fully restored to “as new” condition must meet the following pre-twist angle requirements:

Stage 1 minimum pre-twist angle = 2.07 deg Stage 2 minimum pre-twist angle = 2.55 deg Stage 3 minimum pre-twist angle = 3.50 deg Stage 4 minimum pre-twist angle = 4.70 deg

The Contractor shall ensure that all abradable honeycomb seals are replaced with newly manufactured abradable honeycomb seals on all delivered Module 13/15.

All Modules returned to the Air Force will meet the inspection criteria established in T.O..

Reference CFM56-2B Engine Shop Manual Task 72-00-54-200-001-D, paragraph 3.E. LOW PRESSURE TURBINE ROTOR/STATOR MODULE-INSPECTION. Component parts removed from rotor and frame assembly shall be inspected to piece part requirements outlined for that

OPTIONAL FORM 336 (4-86)

Sponsored by GSA

FAR (48 CFR) 53.110

specific part IAW CFM56-2B ESM. Re-installed components shall be upgraded to the latest configuration required in the latest revision of the CFM56-2B service bulletin manual. All outstanding FAA Airworthiness Directives shall also be incorporated. Specific Service Bulletins requiring compliance include, but are not limited to:

SB 72-0020 Rework of Conical Rotor Support SB 72-0180 Intro of New LPT Case Assy SB 72-0277 Increase in Height of the Abradable Honeycomb on Stage 1 Outer Stationary Air Seal SB 72-0365 Introduction of 3 New Blades with Hardened Teeth for Each Set of Stages 1,2,3 LPT

Blades SB 72-0389 Modification of T495 Bracket and Ring Sector SB 72-0476 Reidentification of LPT Conical Supports and LPT Stub Shafts

SB 72-0496

Antirotation Lock Replacement/Rework/Re-ID Stg 2 & 3 Stationary Air Seal Segments

SB 72-0525 Accident Involved Hardware SB 72-0745 Replacement of Stage 1 LPT Blade 301-330-114-0 and 301-330-115-0

NOTE: Cycle time of blades are not tracked and therefore may not match that of the module. Blades affected by SB 72-0745 need to be replaced regardless of cycle time shown.

The Turbine Frame Assembly is matched with the Low Pressure Turbine Rotor Assembly through #5 bearing adjusting sleeve. The replacement of Turbine Frame or of the #5 bearing support cannot be done without rework of the adjusting sleeve per CFM56-2B, ESM 72-00-03 (Refer to caution in 72-00-56-20 turbine frame removal) after removal and disassembly of the Module. During removal the parts must be identified and match-marked for inspection and installation operations.

The Contractor shall conduct all testing IAW CFM56-2B guidance. The Government reserves the right to witness any and/or all tests conducted by the Contractor and/or subcontractors on a noninterference basis.