lycoming t53-l-13b turbine shaft engine inspection, …
TRANSCRIPT
LYCOMING T53-L-13B TURBINE SHAFT ENGINE INSPECTION, REPAIR AND
OVERHAUL
SCOPE OF WORK
T53-L-13B SOW v2.3 11 June 2019
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TABLE OF CONTENTS
1 SCOPE OF THE WORK ........................................................................................... 3
1.1 BACKGROUND............................................................................................. 3
1.2 PROGRAM CONSTRAINTS ......................................................................... 3
2 PROGRAM MANAGEMENT REQUIREMENTS ....................................................... 4
2.1 CONFIGURATION MANAGEMENT .............................................................. 4
2.2 REPORTING ................................................................................................. 4
2.2.1 Recurrent Reports ..................................................................................... 4
2.2.2 Specific Reports ......................................................................................... 5
2.2.3 Receipt of Component Report ................................................................... 5
2.2.4 Completion Report ..................................................................................... 5
2.2.5 Deviation/Waiver Request ......................................................................... 5
2.2.6 Work Stoppage/Resume ............................................................................ 5
2.2.7 Request for Disposition / Beyond Economical Repair Report .................... 5
2.3 DEVIATIONS / WAIVERS ............................................................................. 5
3 TECHNICAL AND AIRWORTHINES REQUIREMENTS .......................................... 6
3.1 GENERAL REQUIREMENTS ....................................................................... 6
3.2 AIRWORTHINESS AND QUALITY SYSTEM ............................................... 6
3.3 QUALITY CONTROL, INSPECTIONS AND TEST ........................................ 7
3.4 ENGINE CONFIGURATION ......................................................................... 7
3.5 ENGINE TROUBLESHOOTING AND REPAIR ............................................. 8
3.6 ENGINE AND ACCSESORIES MAINTENANCE .......................................... 9
3.7 ENGINE AND ACCSESORIES OVERHAUL ................................................ 9
3.8 REPLACEMENT OF TIME LIMITED PARTS .............................................. 10
3.9 SERVICE BULLETIN APPLICATION .......................................................... 10
3.10 OVER AND ABOVE WORK ........................................................................ 11
3.11 FINAL INSPECTION AND INVENTORY ..................................................... 11
3.12 TRANSPORTATION ................................................................................... 11
List of Acronyms ..................................................................................................... 13
APPENDIX I – RIS Procedure .................................................................................. 14
APPENDIX II – Hellenic Army (HA) specific data .................................................. 15
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1 SCOPE OF THE WORK
1.1 BACKGROUND
1. The NATO Support and Procurement Agency (NSPA) has a requirement to
provide service support contract for Lycoming T53-L-13B Turbine Shaft Engines; P/N 1-000-060-10/-17/-22, NSN 2840-00-134-4803. Service support shall include inspection, repair, modification and overhaul.
2. The purpose of this scope of work (SOW) is to define the technical criteria and tasks to be performed as well as the services and supplies to be furnished by the Contractor to accomplish depot level maintenance (DLM), consisting of, but not limited to, inspection / repair / overhaul and modification of T53- L-13B Engines.
3. The services to be provided will include; a. T53-L-13B Engine Incoming Inspection and report for cost evaluation b. T53-L-13B Engine Repair c. T53-L-13B Engine Modification by implementation of Service Bulletins (SB) d. T53-L-13B Engine Overhaul e. T53-L-13B Engine Accessories Repair, Inspection or Overhaul f. T53-L-13B Engine Replacement of Life Limited Parts g. T53-L-13B Engine records preliminary inspection
4. Contractor will perform maintenance functions on the engine(s), such as,
inspection, measuring, disassembly, remove/install, non-destructive tests (NDT), rework, modification, replace, re-assembly, acceptance, preservation and packaging in the most cost effective manner for NSPA.
1.2 PROGRAM CONSTRAINTS
5. All required services shall be performed at Contractor´s facilities.
6. Transportation of engines from Customer’s depot to Contractor’s facility shall be
responsibility of the Contractor.
7. Capability to simultaneously induct more than one engine and to induct more than 8 engines per year for inspection, repair, modification or overhaul.
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2 PROGRAM MANAGEMENT REQUIREMENTS
This section describes the program tasks to be performed by the Contractor in the different management areas.
2.1 CONFIGURATION MANAGEMENT
8. The Contractor shall be responsible for tracking engine configuration and status to
include incorporation/accomplishment of all technical directives, modifications and inspections. Technical Directives (TDs) consist of:
- Civilian Airworthiness Directives (AD's)
- MAA directives and
- OEM commercial maintenance inspections and modifications to include changes, interim changes, modifications, special instructions for safety of flight, Contractor generated directives, OEM SBs, service instructions, letters, and/or notices.
2.2 REPORTING
9. The Contractor shall deliver to NSPA the reports set forth in this document, and
any relevant information and data related to the performance of the contract that may be reasonably requested by NSPA.
10. All reports shall be prepared using MS Office products (MS Word, Project, PowerPoint or Excel). The Contractor shall deliver electronic copies via e-mail in Microsoft Office Products or in Adobe PDF format or other approved format (such as US Army approved forms – pure edge, IBM, etc).
11. All reports shall be prepared in English.
2.2.1 Recurrent Reports
2.2.1.1 Consumption Usage Report
12. At completion of the maintenance activities on every engine/component, the Contractor shall submit to NSPA a consumption data report. The consumption data report shall include all items and material (including POL) consumed. When an item/component is removed, repaired and reinstalled, the report shall reflect only the parts consumed in the repair process rather than the components that were reused, except for parts with life limit. The repair of Life Limited parts and the relevant consumed items will be mentioned separately in the report.
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2.2.1.2 Engine release to Service Report
13. The Contractor shall prepare and submit to NSPA an acceptance report per engine/component at the end of each service (inspection/overhaul /repair/modification), including test cell results/parameters.
2.2.2 Specific Reports
14. The reports listed under this section are event-triggered and shall be submitted by the Contractor to NSPA for the purpose indicated.
2.2.3 Receipt of Component Report
15. To provide freight tracking data to NSPA for items shipped for service.
2.2.4 Completion Report
16. To report in advance to NSPA the completion of work.
2.2.5 Deviation/Waiver Request
17. To provide data for approval of requests for deviations or waivers to approved technical documents
2.2.6 Work Stoppage/Resume
18. To report anticipated and/or actual work stoppages which will cause TAT to be exceeded or to report work resume after work stoppage.
2.2.7 Request for Disposition / Beyond Economical Repair Report
19. To request permission to exceed contract price for specified services or to recommend scrapping repairable.
2.3 DEVIATIONS / WAIVERS
20. Deviations and waivers, such as Contractor inability to comply with technical
requirements or Contractor’s recommendations for improvements, shall be addressed to NSPA through the Governmental Quality Assurance Representative (GQAR) for evaluation and approval.
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3 TECHNICAL AND AIRWORTHINES REQUIREMENTS
3.1 GENERAL REQUIREMENTS
21. All parts or components that needs to be replaced shall be NEW with zero (0)
hours. If a part or component has calendar limit, minimum three quarters (3/4) of the total calendar limit has to be available upon installation on the engine. However, the Contractor might quote for used parts in case of none availability of new parts. Replacement of the parts or components shall be done only after NSPA approval.
22. The Contractor shall furnish and maintain all tools and equipment. Tools and test
equipment shall be calibrated i.a.w. applicable OEM procedures. Further, configuration of test equipment shall be performed i.a.w. the latest OEM technical documentation and shall be consistent with the configuration of the item being tested. Evidence of certification shall be made available to NSPA upon request.
23. All inputs into engine maintenance records and documentation (Engine Log Book,
Components Log Cards, Release to Service, etc…) shall be in English language written with un-erasable ink.
24. All inspected, tested, repaired, overhauled or replaced items shall be returned with
an Authorized Release Form EASA Form 1 or FAA Form 8130-3 or OEM Certificate of Conformity.
25. Any procedures developed by the repair facility not specified in the prescribed
execution and performance specifications shall be approved through NSPA prior to implementation.
26. All deviations/waivers, Source Approval Requests, Engineering test, etc.,
(including those associated with spare part purchases) shall be submitted in writing and require approval from the NSPA who will liaise with the Customer design activities for all engines.
3.2 AIRWORTHINESS AND QUALITY SYSTEM
27. If the Contractor is not the OEM, then the Contractor shall hold a valid OEM
(Honeywell) T53-L-13B authorized service center certificate for repair and overhaul.
28. The Contractor’s engine test cell(s) shall be correlated back to the OEM.
Correlation certificate may not be older than five (5) years.
29. If subcontracting will be used by the Contractor, the Sub-Contractor shall hold a
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valid OEM authorized repair center certificate for applicable components. In any case, the Contractor shall be responsible to provide all the appropriate certificates for the work performed.
30. The Contractor shall be responsible to maintain validity of the required certificates
during the execution of this contract.
31. Specific airworthiness and quality system requirements per end user are listed in
the appendixes of this SOW.
3.3 QUALITY CONTROL, INSPECTIONS AND TEST
32. The Contractor shall, before and after the engine repair or overhaul, perform an
engine test run in order to certify engine performance and acceptance limits i.a.w. the applicable OEM technical documentation.
33. The Contractor shall perform the acceptance tests necessary to ensure serviceability of the item. The tests shall be those described in the applicable OEM manual.
34. When GQA is required, quality control shall be performed i.a.w. NATO Allied Quality Assurance Publications - AQAP 2131 Ed. C under the terms of NATO STANAG 4107 - Mutual Acceptance of Government Quality Assurance. The Contractor shall grant GQAR access to the facility where the overhaul of the engine is taking place. GQA will be requested, if necessary, at purchase order level.
35. NSPA can, with prior announcement of five (5) working days, conduct government
inspection of the engine/component during repair or overhaul at Contractor’s facilities. The Contractor shall support these inspections with its technical personnel, and provide all necessary data related to the maintenance progress. The Contractor shall grant NSPA team access to the facility where the test, repair overhaul or modification of the engine and its accessories is taking place.
3.4 ENGINE CONFIGURATION
36. Engines and its accessories shall be returned to the customer in the same
configuration as received (except in the case of engine upgrade), with the same type components, accessories, and special equipment installed except as maintained, repaired, removed, or added by the requirements of each case (e.g. SB implementation), unless otherwise stated/ordered by NSPA.
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37. T53-L-13B engine will be send to the Contractor for testing, repair, overhaul or modification with all of its accessories attached, unless otherwise specified in the purchase order.
38. Specific Customer Engine configuration is described in the Annexes of this SOW.
3.5 ENGINE TROUBLESHOOTING AND REPAIR
39. Troubleshooting and repair activities shall be performed i.a.w. the current version
of the OEM documentation.
40. NSPA will deliver the engine with Forms and Records i.a.w. DA PAM 738-751. All the discrepancies will be described in the DA FORMS 2407 & 2410.
41. The Contractor shall perform engine troubleshooting by performing incoming inspection and test bench test i.a.w. OEM standards not later than fifteen (15) calendar days after receipt of the engine. If the condition of the engine does not allow execution of the bench test, then this part of the troubleshooting can be revoked. The contractor shall notify NSPA if such a condition exist before continuing with further maintenance actions.
42. Main purpose of incoming inspection and test bench is troubleshooting and
identifying engine performance. Upon completion the contractor shall issue a detailed report to the NSPA that will include but is not limited to:
- Engine basic data and list of components (aggregates) with P/N, S/N,
TSN and TSO, - findings from the induction inspection and bench test, - performance results from the test bench, - identification of damaged parts and/or components, - repair quotation i.a.w. RIS procedure, and - conclusion.
43. The Contractor’s test cell shall be correlated back to the OEM. The test equipment
shall be calibrated i.a.w the applicable OEM procedures. Further, configuration of test equipment shall be performed in accordance with the latest OEM technical documentation and shall be consistent with the configuration of the item being tested. Evidence of certification shall be made available to NSPA on request.
44. The NSPA and the Customer representative can, with prior announcement, be present during engine cell test. The Contractor shall grant NSPA team access to the facility where the engine bench test is taking place. The Contractor shall support this visit with its technical personnel and provide all necessary data related to the test progress.
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45. Components that are found to be unserviceable shall be either repaired or replaced with an exchange component in the frame of the agreed TAT of the engine inspection.
46. The repair or replacement activities of these components shall be treated as over
and above via RIS procedure (Appendix I).
47. Upon completion of the repair the contractor shall again perform engine test bench
according to the OEM standards. Results from the test cell shall be send to the NSPA in order to evaluate the results.
3.6 ENGINE AND ACCESSORIES MAINTENANCE
48. Engine and accessories may require execution of periodic maintenance actions
during the engine repair. The Contractor shall be responsible to execute maintenance actions as requested by NSPA in the Purchase Order (PO).
49. Maintenance activities shall be performed i.a.w. the current version of the OEM maintenance documentation.
50. The Contractor shall perform the analysis of the engine and aggregates
maintenance status in order to ensure that all engine maintenance up to 600 H shall be accomplished. If the Contractor determines that component or accessory is scheduled for maintenance, as per above criteria, and has not been ordered by the NSPA PO, then the Contractor shall report this to the NSPA to seek further guidance on how to proceed.
3.7 ENGINE AND ACCESSORIES OVERHAUL
51. Overhaul activities shall be performed i.a.w. the current version of the OEM
overhaul documentation.
52. The Contractor shall perform the analysis of the engine and aggregates overhaul status in order to ensure that they have a minimum remaining overhaul time of at least 600 H. If the Contractor determines that component or accessory has remaining available overhaul time less than 600 H and the overhaul has not been ordered by the NSPA PO, then the Contractor shall report this to the NSPA to seek further guidance on how to proceed.
53. The Contractor may be required to correct other discrepancies not part of the overhaul process that are required to release the engine/components to service. This additional work (over and above) shall be quoted independently by the
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contractor and submitted for approval to the NSPA using the form attached in Appendix I (RIS procedure).
54. All overhauled items shall be returned with an EASA Form 1 or FAA Form 8130-3
or with a Certificate of Conformity and appropriate US Army forms i.a.w. DA PAM 738-751.
3.8 REPLACEMENT OF LIFE LIMITED PARTS
55. The Contractor shall perform the replacement of life limited parts and accessories
during repair or overhaul process.
56. The Contractor shall perform the analysis of the installed life limited components and accessories in order to ensure that they have a minimum remaining life of at least one 600 H. If the Contractor determines that component or accessory has remaining time less then requested 600 H, then the Contractor shall report this to the NSPA.
57. Replacement of life limited parts that are not defined as standard replacement
parts in the scope of requested work shall be treated as over and above via RIS procedure (Appendix I).
3.9 SERVICE BULLETIN APPLICATION
58. The Contractor shall indicate all the OEM SBs that may potentially be incorporated
on every engine after incoming inspection. The list of potential SBs to be incorporated (including mandatory and optional) shall be submitted to NSPA for evaluation and approval including price and impact on TAT (if any) per SB.
59. The Contractor shall provide, unless otherwise specified, all the material required to implement the approved SBs.
60. During the maintenance activities the Contractor shall inform NSPA of all
applicable civilian Airworthiness Directives (AD) and request for further instructions.
61. During the maintenance activities the Contractor shall inform NSPA of all
applicable OEM mandatory or alert SB and request for further instructions.
62. AD and SBs shall be treated as work over and above via RIS procedure (Appendix I), except ALERT SBs.
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3.10 OVER AND ABOVE WORK
63. Any over and above (O&A) work identified after engine delivery to the Contractor
and not covered by the SOW shall be treated as over and above and shall be quoted by the Contractor. Such quotation shall be submitted to NSPA for approval via RIS procedure (Appendix I).
64. Over and above quotation shall include (as a minimum) a cost breakdown of the
required materials and labor. Furthermore, any impact on the overall TAT shall be indicated. In a case of high price material or extensive labor costs the Contractor shall provide together with RIS also technical reports and pictures of the discrepancy.
65. No work on the specific equipment shall be done until RIS is approved by NSPA.
3.11 FINAL INSPECTION AND INVENTORY
66. A final inspection and inventory check shall be performed before an engine leaves
the Contractor’s facility. Items shall be inspected to determine their configuration and to verify the correctness of the part number.
67. Serviced engine(s) and the complete engine records, forms and work documents shall be presented to the GQAR and to the Customer Representative or the Contactor's Senior Quality Inspector in accordance with NSPA instructions, who will accept the work on behalf of NSPA and release it.
68. Work performed and replaced parts (tracked items only) must be indicated on the Historical Data Report.
69. Identification of modified items shall be changed as indicated in the relevant
modification order and respective logbooks updated accordingly.
70. As far as applicable, all replaced flight safety critical parts shall be destroyed
(standard aviation procedures applies) at contractors site.
3.12 TRANSPORTATION
71. In general, the transportation of the engines to and from the Contractor’s facility
shall be Contractor’s responsibility. Alternatively, NSPA reserves the right to deliver the engines to the Contractor’s facility. In any case the Contractor will be informed accordingly when the Purchase Order (PO) is issued.
72. Engine pick-up and delivery address is specified for each customer separately in
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the specific customer Appendixes that are part of this SOW.
73. The Contractor is responsible for selecting packaging methods and materials i.a.w. commercial practices to provide adequate protection to the returned item(s) at minimum cost. Packaging methods and materials selected should consider, as a minimum, the part's physical characteristics, size, weight, fragility, transportation mode and environment. Care should be exercised for hazardous materials and Electrostatic Discharge (ESD) as to ensure proper handling.
74. Each engine shall be packaged and identified separately. Without specific
instructions, all items shall be packed in suitable containers for protection in shipment and storage, and i.a.w. applicable specifications. Contractor shall provide packing sheets, in duplicate, located with one (1) copy affixed to the container exterior and another copy located inside the container. Each container of a multiple container shipment shall be identified to show the number of the container and the total number of containers in the shipment, and the number of the container in which the packing sheet has been enclosed.
75. Containers may be requested to be provided by the Contractor on a loan basis.
Loan cost shall be quoted by the Contractor on a case by case basis.
76. All shipments, or items prepared for shipment by the Contractor, shall include packing sheets containing end-user identification, NSPA’s Contract number, engine/component serial number, quantity, part number, description of the items shipped, and appropriate evidence of inspection.
77. Any labels required by the material, especially material handling caution labels
i.a.w. IATA regulations and international regulations for the transport of dangerous cargo (i.e., Hazardous Material, ESD Sensitive, fragile) shall also be affixed to the outside of the container.
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List of Acronyms
AD Airworthiness Directive
AQAP Allied Quality Assurance Publications
EASA European Aviation Safety Agency
ESD Electrostatic Discharge
FAA Federal Aviation Administration
GFE Government Furnished Equipment
GQA Government Quality Assurance
GQAR Government Quality Assurance Representative
i.a.w. In accordance with
ISO International Standard Organization
MS Microsoft
NATO North Atlantic Treaty Organization
NSPA NATO Support Agency
OEM Original Equipment Manufacturer
RIS Repair Identification Sheet
SB Service Bulletin
SOW Scope of Work
STANAG Standardization Agreement
TAT Turn Around Time
TBO Time Between Overhaul
Table 1: Acronyms
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APPENDIX I – RIS Procedure The RIS (Repair Identification Sheet) procedure has to be applied for all findings which occur during the performance of the phase inspection of the related helicopter. The RIS procedure identifies all findings, parts, man hours, influence of TAT and costs related to an identified finding.
RIS Sheet (empty)
Reg.:
Customer:
Module o
Accessory Equipment o
Type: S/N fh cycles RIS no: Rev.:
Classification Yes: No: Corrosion: Other:
Affect TAT: Yes: No:
Affected Part: ATA: Sub ATA: Zone:
Defect description:
Findings due to:
Manual ref.:
Suggest repair scheme:
Materials required:
(Estimated units
and quantity)
PN Desc. EA Price Handling Fee
[%]
Cost element Technician Engineering
Amount(EURO)
Perform i.a.w. RIS? YES: NO:
Remarks:
TotalMaterials Shipping & Others
MAINTENANCE
REPAIR IDENTIFICATION SHEET
Affect CRS
If yes, define TAT extension:
Contract no /
reference:
Date:
Recommended by: Sign:
Date:
Date: Sign: Customer representative (COR)
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APPENDIX II – Hellenic Army (HA) specific data
I. NATO AQAP Requirements GQA is not required.
II. HA Maintenance Policy Hellenic Army T53 engine policy is :
a) Engine O/H every 2400hours. b) Hot End lnspection (HEI) every 600 hours. c) Fuel control O/H every 2500 hours and midlife inspection every 1250 hours
III. Engine Transportation
Address for engine transportation pick-up and delivery is: HELLENIC ARMY STRATOPEDON PAPASTATHI 651 BASE ORD DEPOT (651 ABYP) 3rd MATERIAL BATTALION (3 TYL) BST 902 GR 13671 FILADELPHIAS 123-MENIDI ATTIKI ATHENS-HELLAS IV. T53-L-13B Engine Configuration: Life Limited Parts
NOMENCLATURE PART NO. NSN
SECOND PT DISC 1-140-272-01 1-140-272-04 1-140-272-08
2840-01-943-2215 2840-01-008-5986 2840-01-481-2380
FIRST PT DISC 1-190-009-05 1-190-009-11
2840-00-925-9560 2840-01-481-2383
ROTOR SUBASSEMBLY 1-101-250-03 1-101-250-04
2840-00-176-3746 2840-01-154-7142
FRONT COMP SHAFT 1-100-495-07 1-100-495-03
2840-01-006-1118 2840-00-776-3750
REAR COMP SHAFT 1-100-501-01 1-100-495-03
2840-00-176-3751 2840-00-176-3750
POWER SHAFT 1-100-800-04 2840-00-943-2206
PT SPACER 1-140-169-03 1-140-169-04 1-140-169-07
5365-01-217-4692 5365-01-008-5947 5365-01-217-4692
IMPELLER CENTRIF. COMP 1-100-078-13 1-100-078-07 1-100-078-08
2840-01-304-1058 2840-00-176-3745 N/A
FIRST GP SEAL DISC 1-100-135-03 1-100-135-15
2840-00-925-2972 2840-01-481-0822
FIRST STAGE GP DISC 1-100-035-01 1-100-133-01
2840-01-481-2384 2840-00-924-7933
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SECOND STAGE GP DISC 1-100-063-05 1-103-038-01
2840-00-924-8521 2840-01-481-2381
GP SPACER 1-100-294-03 1-100-294-11
5365-00-947-6225 5365-01-481-0824
FUEL CONTROL UNIT 1-170-780-01 1-170-240-60
2915-01-459-8654 2840-01-005-9197
GOVERNOR OVERSPEED 1-160-850-23 1-160-850-16
2915-01-459-3248 2915-01-005-9196