Combined Synopsis / Solicitation for Mission Analysis and Engine Life Limited Parts Assessment 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 support to identify updated Life Discipline Manual (LDM) Confidence Factors and Life Limits for the CFM56-7B27AE of the United States Navy (USN) P-8A fleet based on historical flight data.

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.

Mission Analysis and Engine Life Limited Parts Assessment support services for the United States Navy (USN) 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 able to gather the required performance data will be considered as a qualified source. The scope of work is as follows:

The USN P-8A CFM56-7B life limits for critical components developed for the program’s introduction in 2011 were conservative to provide margin against the unknown effects of converting the commercial Boeing 737 platform to military use. This was partially addressed with the release of partial cycles (SB72-0988 & SB72-1058) but did not assess or update LDM Confidence Tables and their underlying analyses.

With over a decade of operational experience and historical flight data available for analysis, the platform is sufficiently mature for the planned reassessment to occur. The USN NAWCAD engineers shall provide flight data for the CFM56-7B fleet to the Contractor for a mission analysis, LDM factor assessment, and life limit assessment.

The Contractor shall assess the flight data to determine the impact of the operational conditions and mission and to establish the thermal and stress state of all Chapter 5 life-limited components and critical rotating parts with recommended removal schedules.

They shall update the low-cycle fatigue (LCF) material properties applicable to each component, identify LCF life for each component, calculate the Life Discipline Manual (LDM) Confidence Factors, calculate engine component operational lives, and recommend component life limits and inspection schedules. Additionally, the Contractor shall identify efforts required to refine the confidence factors for life-limited components.

Upon completion of the life limit assessment, the Contractor will be tasked with delivery of updated LDM Confidence Table, LCF life, and recommended life limit and inspection schedule, as applicable. Requirements of this effort are as follows;

1. Work Planning The Contractor shall provide support and documentation, including a statement of work (SOW), rough order of magnitude (ROM) cost, and plan of action and milestones (POAM) for performance of the life assessment work as outlined in this document, for all Chapter 5 life-limited components and critical rotating parts with recommended removal schedules applicable to USN CFM56-7B27A/3 and –7B27AE engines (Appendix B). Additionally, the Contractor shall identify future efforts, such as piece part inspection, that would validate lifing analyses and improve the confidence factors within the LDM Confidence Table.

2. Life Management Process Review The Contractor shall provide USN personnel a fundamental review of the life assessment process for the P-8A CFM56-7B27A/3 and -7B27AE engine at the initiation and conclusion of this effort. The reviews shall include fundamental assumptions in the life assessment process and address the effects of damage mechanisms contributing to these assessments, including fatigue, wear, corrosion, and any other mechanisms considered, if applicable.

The reviews shall also identify individual life assessment requirements or caveats for individual components and/or critical features. These reviews shall be performed via in-person and/or teleconference virtual meeting(s), and all supporting slides, visual aids, charts, and other media used to facilitate this discussion shall be provided to USN personnel.

3. Mission Mix Assessment The Contractor shall conduct and report a mission mix assessment on the operational conditions of the identified components (Appendix B) for A/3 and AE engine configurations based on flight data, pilot surveys, and other historical data and present the findings of that assessment with USN.

USN shall provide flight data to the Contractor for the purposes of mission mix assessment, including subpopulations of flight data that may correspond to specific configurations or operations (e.g., air-to-air refueling, engine version, location). The Contractor shall define major/minor cycle definitions and partial cycle factors as well as identify the parameters and calculation methods used to determine engine cycle counts.

These cycle counts shall be calculable using decoded flight data available on the ground health monitoring system (GHMS) and used to determine engine cyclic damage content (GHMS processes full-flight downloads from the engine flight data recorder).

A mission mix assessment report shall include major and minor cycle definitions and cycle type gates, mission profile characteristics, take-off ambient temperature mix, pre-flight ground idle distributions, and variability of fleet operations (e.g. variation across engines, locations, and seasons).

4. Life Assessment (Appendix B Components Excluding Fan Blades) The Contractor shall conduct a life limit assessment inclusive of but not limited to the components listed in Appendix B, excluding fan blades, and as applicable to the AE engine configuration in accordance with the commercial engine LDM and best practices. Key conditions of interest for analysis include steady-state and transient conditions (such as cruise and takeoff) and engine health state at the timestep of the min and max strain (and/or stress).

At a minimum, the following analyses shall be performed: Thermomechanical Analysis The Contractor shall perform static and transient heat transfer and stress analysis for each component, each contractor-identified critical location, and each mission type as determined from the operational condition of the components.

Material Analysis, Fatigue, and Risk The Contractor shall conduct analysis inclusive of material properties applicable to each component and contractor-identified critical location across each mission category, including low cycle fatigue (LCF), high cycle fatigue (HCF), and/or other applicable life limiting fatigue modes. Fatigue analysis should consider multiple R-ratios and cyclic load configurations based on the thermal and stress analyses.

LDM Confidence Factors The Contractor shall report LDM Confidence Tables based on historical flight data and cycle accumulation, physical component testing and inspections, modeling and simulation, and/or other methods as applicable. This LDM Confidence Table shall include, but is not limited to, all components listed in Appendix B across each mission category and critical location.

Life Limits and Inspection Schedule The Contractor shall report the Operational Life, Recommended Life Limits, and Inspection Schedule inclusive of but not limited to all components listed in Appendix B as applicable to the AE engine configuration across each mission category and critical location. The Contractor shall evaluate the applicability of inspection intervals and/or service bulletin removal and replace limits on the HPT blades.

Upon USN concurrence, the Contractor shall publish Chapter 5 updates and if applicable, Service Bulletin(s) in support of updated component-level life limits, removal schedules, and inspection schedules.

5. Life and Inspection Assessment for Fan Blades The Contractor shall report the Recommended Inspection Threshold and Interval Schedule inclusive of, but not limited to, fan blades as identified in Appendix B and as applicable to the AE engine configuration and provide an assessment summary, inclusive of assessment assumptions, analyses results, and Confidence Factors, as applicable.

6. Over-the-Shoulder Technical Review The Contractor shall provide USN engineers with the opportunity to review the technical documentation as determined to be shareable by CFM engineering that supports the deliverables and requirements of Section (4). USN may not direct further analysis or work under this SOW based upon the over-the-shoulder review.