Combined Synopsis / Solicitation for Borescope Certification in support of the F108 Engine

This notice serves as DLA Aviation’s combined synopsis/solicitation as described in FAR 12.603, in accordance with FAR 5.201 and the approved J&A, for addition of providing certification of the Click-Loc borescope plug set use on the CFM56-2 engines (USAF F108) and releasing of a service bulletin documenting the approved application of this borescope plug set for use on the CFM56-2 engine configuration. for the United States Air Force. Addition to sole source Long Term Contract SPE4AX-25-D-9406 to CFM International Inc. (CFM), Contractor and Government Entity (CAGE) code 58828.

This is a FAR part 12 effort being added to the current contract SPE4AX-25-D-9406.

Borescope certification support services for the United States Air Force (USAF) are being solicited to be added to contract SPE4AX-25-D-9406, awarded to CFM International Inc. CAGE 58828. Actual requirements for the additional scope will be negotiated and added to the basic contract. Individual requirements are certified as sole source to CFM and synopsized in accordance with FAR 5.201.

DLA Aviation will issue a letter solicitation (RFP) to the sole source Original Equipment Manufacturer (OEM). If any non-OEM source is interested in any of the NSNs, please notify the Contracting Officer prior to the combined synopsis/solicitation closing date. A copy of the letter of interest should be forwarded to the Contracting Officer identified herein. The Government may alter the acquisition strategy if it is in the best interest of the Government. In order to receive an award, you must be registered in the System for Award Management (SAM). SAM registration is at https://www.sam.gov.

It is anticipated that this requirement will be added as a separate line item to the current sole source CFM COI contract SPE4AX-25-D-9406.  The data required to perform the necessary services is CFM’s proprietary and confidential commercial intellectual data and cannot be shared or provided by the Government. Only sources with access to the CFM56-2 series of engines performance information will be considered as a qualified source.

The scope of work is as follows:

The US Air Force F108 engine fleet has experienced breakages of the borescope plugs which can lead to FOD damage and presents a challenging effort to remove the broken pieces. These breakages are manifested in the 3 borescope plugs located at the stage 7, stage 8 and stage 9 positions of the high pressure compressor. Along with the breakages of these 3 plugs, all borescope plugs require safety wire as a redundant feature to ensure the plugs are locked in place. This results in extensive and unnecessary mission downtime as well as maintenance time to complete the laborious task of applying safety wire to all the plugs. The new self-locking borescope plug set consists of 15 new borescope plug assemblies that incorporate a new self-locking feature, which eliminates the requirement for safety wire. The new plug design also employs a more robust design for the compressor plugs at stage 7, stage 8 and stage 9 which eliminates the cause of breakages. So, the new borescope plug set reduces maintenance time as it eliminates the need for safety wire and reduces failures with a stronger plug at the vulnerable areas.

The contractor shall perform all necessary tasks required to achieve certification of the Click-Loc borescope plug set use on the CFM56-2 engines (USAF F108) and release a service bulletin documenting the approved application of this borescope plug set for use on the CFM56-2 engine configuration.

Both the Original Engine Manufacturer (OEM) and the Air Force have experience with this type of self-locking design. However, the experience is on engines that have a different mission profile and the parts in use are not borescope plugs. It is necessary to have the engine manufacturer perform all necessary reviews and analysis to verify and validate the application of the borescope plug set on the CFM56-2 engine fleet. 

The contractor will perform all necessary analysis on the proposed design as well as develop any testing identified as needed for validation of functional capability in the CFM56-2 engine configuration. Analysis tasks can include but are not limited to review of usage history on other engine fleets with similar parts, modeling, comparative assessment between the existing borescope plugs and the proposed new plugs as well as review of certification efforts on other OEM engine fleets. The contractor will evaluate to determine if any validation test plans are necessary and develop those plans as necessary based on validation needs of the contractor. Included in this effort are any tasks necessary to evaluate and establish industrialization of the borescope plug set with CFMI.

Once the contractor has completed the needed analysis and evaluation of the proposed new borescope plug set, they will submit findings and results through their review process. Successful review will then drive a service bulletin draft and release to the FAA and the US Air Force allowing use of the new borescope plug set on CFM56-2 engines.

Requirements of this effort are as follows;

1. The Contractor shall review provided design data for the self-locking borescope plug set. This data will include the part drawings and established specifications as well as validation test plans and results.

2. The Contractor shall review all current engine fleets that have similar designed features to determine if their experience is applicable for evaluation of the new design for the CFM56-2 fleet

3. The Contractor shall determine and run whatever analysis models necessary to evaluate the new design.

4. The Contractor will determine if a validation plan is necessary for approving the new borescope plug set for use in the CFM56-2. If a validation plan is necessary, they will then develop the test plan and execute all tests necessary to approve the new design.

5. If the new borescope plug set is approved for the CFM56-2 engine, the contractor will draft and release a service bulletin to authorize use of the new design in the CFM56-2 engine fleets.