6973GH-22-R-00218 Statement of Work .pdf

CF34‐3A1 Jet Engine Overhaul

Services

Statement of Work

Table of Contents

Contents

1.0 INTRODUCTION

2.0 SCOPE

3.0 CONTRACTOR RESPONSIBILITIES

3.1 Contractor Engine Overhaul Requirements

3.2 Replacement Asset/Equipment Condition and Documentation

3.3 Contractor Over & Above (O&A) Support

3.4 Component Warranty

3.5 Contractor Personnel

3.6 Workplace Drug Free Program

3.7 Government Property

4.0 FAA RESPONSIBILITIES

4.1 FAA Engine Overhaul Maintenance Scheduling

4.2 FAA Engine Maintenance Authorizations

4.3 FAA Engine Configuration and Maintenance Data

5.0 PARTS AND MATERIAL REQUIREMENTS

5.1 Time Controlled Parts

5.2 Components/Parts Replacement and Exchange

5.3 Core Part Return

5.4 Disposition of FAA Owned Parts Removed

6.0 FAA ACCEPTANCE AND INSPECTION

6.1 Engine Inspection and Maintenance Documents

7.0 OVER AND ABOVE (O&A) TASKS AND PROCEDURES

7.1 Over and Above (O&A) Task

7.2 Over and Above (O&A) Procedures

8.0 TRAVEL FOR MEETINGS OR REVIEWS

9.0 PERIOD OF PERFORMANCE

10.0 PLACE OF PERFORMANCE

CF34‐3A1 JET ENGINE OVERHAUL SERVICES

STATEMENT OF WORK

1.0 INTRODUCTION

The Federal Aviation Administration (FAA) owns and operates three (3) Challenger 601 aircraft.

These aircraft utilize two General Electric (GE) CF34‐3A1jet engines per aircraft. The FAA Challenger aircraft are typed certified and modified to meet specialized FAA mission requirements.

This procurement effort is to provide one (1) CF34-3A1 jet engine overhaul with the option to add two (2) additional engine overhauls. This effort will also include associated engine removal, installation, packing and shipping. Overhauls will be accomplished at an FAA authorized service center.

2.0 SCOPE

The contractor must perform work at an authorized FAA authorized service center with a 14 CFR Part 145 Repair Station Certificate and associated Operation Specifications listing the appropriate ratings and limitations, have access to the original equipment manufacturer (OEM) engineering support, and the ability to perform overhaul maintenance.

The contractor must have the approved tooling and equipment to properly overhaul General Electric CF-34A1 engines. The contractor must correct all non-routine discrepancies discovered during the overhaul and perform an airworthiness release in accordance with Flight Program Operations’ FAA- approved Continuous Airworthiness Maintenance Program (CAMP).

The overhaul program must provide coverage for the cost of engine overhauls including parts, labor. The contractor must provide for the removal, packing, transportation (e.g., shipping), and re-installation of the overhauled engine at the FAA Aeronautical Center in Oklahoma City, OK (KOKC) or at a mutually agreed upon location.

The contractor must also have a CF34-3A1 engine available for lease if needed to avoid extending aircraft down time. The leased engine may be installed on the aircraft during the engine overhaul, and certified as airworthy.

The other support tasks and services described in Section 7.0 will be considered as Over & Above (O&A) actions. The other support tasks and services are necessary to complete the overhaul of the engines to an airworthy condition that ensures the airworthiness, and hence availability of the aircraft for operational use.

All facilities and parts used in support of this contract will be subject to surveillance and acceptance by the FAA Flight Program Operations Quality Assurance Section.

3.0 CONTRACTOR RESPONSIBILITIES

3.1 Contractor Engine Overhaul Requirements

The contractor shall provide General Electric (GE) CF-34-3A1engine overhaul services consisting of teardowns, evaluations, and inspections. All maintenance performed under this contract must be performed by experienced General Electric CF-34-3A1 technicians. The repair facility must be certified under the CFR Part 145. Engine parts and components used to complete the overhauls of the GE CF-34- 3A1 engines must have a valid certification required by CFR, Title 14.

The contractor must provide a teardown and evaluation report for the GE CF34-3A1. This teardown and evaluation report must include time and materials. A copy of the maintenance service report must be part of the recertification documents (8130-3) packet that must be provided to the FAA when the overhaul is complete.

After receipt of the teardown and evaluation report, the price of the overhaul will be negotiated and finalized with the FAA contracting officer (CO) and the contractor. No overhaul work shall begin until the price is finalized unless specifically authorized by the FAA CO or his/her designee.

The contractor shall be responsible for the freight cost of shipping engines to and from the overhaul facility. The contractor will provide GE CF-34-3A1 approved shipping containers for all shipping. The contractor will provide labor necessary to perform engine removals and installations as each overhaul is scheduled.

The contactor must ensure that the engine logbooks are properly completed in accordance with Flight Program Operations’ FAA-approved CAMP and FAA-accepted General Maintenance Manual (GMM), as applicable, following any maintenance completed by the contractor/subcontractor.

3.2 Replacement Asset/Equipment Condition and Documentation

Any parts required to accomplish the overhaul or to correct discrepancies discovered during the performance of overhaul may be procured or purchased by the contractor with prior authorization from the FAA Contracting Officer (CO) or Contracting Officer Representative (COR). Any asset(s) required to replace existing component(s) necessary for the accomplishment of the contracted work must meet the following requirements:

Reasonable Parts Handling markup/surcharge fees will be negotiated by Federal Aviation Administration CO and Contractor prior to contract being awarded and must not exceed 10%. All shop fees must be included in the overhaul/unscheduled maintenance, which will be considered over and above tasks, price and not separately priced.

Any asset(s) required to replace existing component(s) necessary for the accomplishment of the contracted work must meet the following requirements:

Components offered as “New” must:

Have zero (0) hours and zero (0) cycles in service since time of manufacture, and the internal components must have (0) hours and zero (0) cycles in service since time of manufacture.

Have documentation that provides full traceability of parts and assemblies, if applicable, and a copy of the original shipping invoice from the Production Approval Holder (PAH) to the supplier providing evidence that the origin of the part is from a FAA PAH or that the original acquisition was from a FAA-approved source.

Have documentation that identifies assembly internal components that are required to be tracked for traceability in accordance with the OEM manuals. Documents must identify part number and serial number.

Components offered as “Overhauled/Repaired/Serviceable” must:

Be restored by an FAA-approved 14 CFR Part 145 Repair Station in accordance with the OEM manual requirements.

Be restored after January 1, 2011 and have zero (0) time and zero (0) cycles in service since time of restoration.

Have documentation that identifies all assemblies and assembly components meet the OEM 120-month restoration requirement.

Have documentation that identifies assembly internal components that are required to be tracked for traceability in accordance with the OEM manuals. Documents must identify part number, serial number, and times/cycles/landings since new or overhaul.

All components must:

Be properly identified as an approved aeronautical part in accordance with 14 CFR Part 21 and 14 CFR Part 45.

Have a shipping invoice from the contractor to the FAA identifying part numbers and serial numbers.

3.3 Contractor Over & Above (O&A) Support

The Contractor must provide General Electric (GE) CF-34-3A1 engine overhaul maintenance services under this contract using engine overhaul facilities that are General Electric approved, FAA approved, and have GE CF-34-3A1 experience.

The FAA has a need for the contractor to provide maintenance, parts, and support tasks.

These tasks are necessary to support maintenance of the FAA GE CF-34-3A1 engines and maintain availability of the Challenger 601 aircraft.

Additional, unscheduled maintenance services, parts, and support tasks will be considered as O&A actions and are described in Section 7.0 O&A Tasks and Procedures.

O&A actions must be billed on a separate Contract Line-Item Number (CLIN)—the

“Unscheduled Maintenance” CLIN. The Contractor must receive prior authorization from the FAA Contracting Officer (CO) or their designated representatives, Contracting Officer Representative (COR), before providing O&A maintenance, parts, or support tasks.

3.4 Component Warranty

The contractor shall provide a written statement of warranty for the work performed for the FAA.

The warranty statement must identify what is covered under warranty and the warranty duration.

3.5 Contractor Personnel

The contractor must employ personnel who possess the necessary skills to effectively accomplish the requirements of this Statement of Work. The skills must include technical support for engine troubleshooting and diagnosing, engine overhaul services, parts support required for engine overhauls, engine removals and installs, and provide accounting support for invoicing as described in this SOW.

3.6 Workplace Drug Free Program

The contractor must maintain a drug-free facilities and maintain a drug-testing program as required by Department of Transportation (DOT). Program must include screening of all new employees and ongoing random testing of all employees that will be providing maintenance and overhaul services under this contract.

3.7 Government Property

An inventory of loose equipment will be performed, and the property will be stored as Government Property (GP) and returned with the aircraft upon completion of the maintenance.

GP shall be stored in a secure location.

4.0 FAA RESPONSIBILITIES

4.1 FAA Engine Overhaul Maintenance Scheduling

The FAA will schedule GE CF34‐3A1 engine maintenance to comply with requirements IAW GE manuals, advisories, and technical specifications. The FAA will notify the contractor of scheduled engine overhaul requirements at least ninety (90) days prior to them becoming due.

4.2 FAA Engine Maintenance Authorizations

The FAA or their designated repair facility will request maintenance and parts authorizations as described by the Contractor for work to be accomplished IAW this

SOW.

4.3 FAA Engine Configuration and Maintenance Data

The FAA will provide engine configuration and maintenance data upon the Contractor’s request. The data provided will be from the FAA tracking systems database and/or from the GE CF34‐3A1 engine logbooks.

5.0 PARTS AND MATERIAL REQUIREMENTS

5.1 Time Controlled Parts

Time controlled parts are parts where time has expired and must be replaced with new or overhauled parts. When time-controlled parts have failed, but time has not expired, they may be repaired and used on the FAA GE CF34‐3A1 engines provided the part have sufficient life to achieve its next major scheduled event where access to such part is permitted.

5.2 Components/Parts Replacement and Exchange

Engine components/parts that are removed and exchanged during maintenance of the FAA engines will no longer be the property or responsibility of the FAA. The replacement of newly embodied engine components/parts will become the property of the FAA. All exchange components/parts removed from engines during maintenance by FAA personnel will be returned to the Contractor or their designated supplier in an “as‐is condition”.

5.3 Core Part Return

In those instances when a simultaneous exchange of parts is not feasible, the Contractor must allow the FAA to return the core part within a fourteen (14) day period. If the FAA does not return the part within the fourteen (14) day period, the Contractor must provide notification to the FAA of the past due core. If the FAA is unable to return the core part due to the Contractor, the part may be deemed lost. The Contractor will provide the FAA the value of the part. Upon approval of the FAA, the Contractor may invoice the FAA for the value of the part using the O&A procedure.

5.4 Disposition of FAA Owned Parts Removed

Each part removed by the contractor from a FAA owned engine, not reinstalled therein, or is not replaced or exchanged by the contractor is the property of the FAA. Such parts must be identified with a tag attached to each part that identifies “FAA Property”, part number, component serial number, cause for removal, and serviceability if known. The parts must be returned to the FAA with a shipping document that lists each part and quantity.

6.0 FAA ACCEPTANCE AND INSPECTION

The FAA will conduct a receiving inspection of all incoming engines and parts IAW Technical Inspection (TI) 4100.24, General Maintenance Manual. Any engines and parts received in a damaged condition or without proper certification documentation will be recorded and identified to the Contractor for resolution. Should the engines or parts require return shipment to the Contractor it will be at the Contractor’s expense.

6.1 Engine Inspection and Maintenance Documents

Upon completion of engine inspections, maintenance, repair, etc. the Contractor must provide all certification documents including full copy of work order that describe all details of inspections performed, maintenance performed, components repaired or replaced, problem areas, etc. The Contractor must enter in the historical records (engine logbooks) all FAA airworthiness directives, manufacturers’ service bulletins or other modifications, and all other significant maintenance actions accomplished. In addition, the Contractor must record all previously complied with modifications found to be previously accomplished, but not recorded. The Contractor must indicate in the historical records the nomenclature, part number, location, total time, and total cycles, accumulated for all replacement life limited parts (LLP) installed. Any LLP parts that are repaired, reworked, or modified that extend or reduce life will be identified with new limits in the historical records.

7.0 OVER AND ABOVE (O&A) TASKS AND PROCEDURES

The Contractor must provide Over & Above (O&A) support. Additional maintenance, parts, and support task that are not covered under the cost per engine operating hour task will be considered as O&A. These tasks are necessary to support maintenance availability of the FAA Challenger aircraft.

7.1 Over and Above (O&A) Task

The Contractor must receive prior authorization from the FAA CO or COR before providing O&A maintenance, parts, or support task. The O&A tasks include but are not limited to the following:

1. Parts – Necessary engine parts or components not fixed priced in the pricing matrix or negotiated after teardown, test, and evaluation may be paid for via the O&A (a.k.a.

Unscheduled Maintenance) CLIN. Note that O&A is linked to a T&M CLIN and that parts are supplied at cost plus a reasonable handling fee as defined in Section 7.2.

2. Labor – Labor, or “Time,” that is not allocable to a separate CLIN on a fixed price or cost reimbursable basis, may be allocated and paid for via O&A.

3. Foreign Object Damage (FOD) – Repair of damage to the engines resulting from foreign object damage, i.e., hail, bird strikes, rocks, or other debris.

4. Damage/Loss –Repair/replacement of parts or components either damaged or lost because of negligence or accident on the part of the FAA.

5. Theft – Replacement of parts because of theft of parts or components from engines other than when in control of the contractor.

6. Acts of GOD – Repairs due to flood, earthquake, volcanic ash, lightning strikes, tornadoes, hurricanes, other local emergencies, etc.

7. Corrosion, Erosion, or Sulphidation – Component repair or replacement costs attributable to damage caused by corrosion, erosion or sulphidation.

8. Service Bulletins – Cost of engine or component Service Bulletins requested and approved by the FAA not covered by the Engine Management Program on a cost per engine operating hour basis.

9. Support Equipment, Materials, Manuals, Technical Support – Cost of support equipment rentals, materials, manuals, technical support, etc. that is not covered by the cost per engine operating hour Engine Management Program.

10. Spares Parts Purchases – Purchase of spare parts less discount for FAA stock.

7.2 Over and Above (O&A) Procedures

Either the FAA or the contractor may initiate the O&A action that meets the criteria. If the FAA determines an O&A action is required, the FAA CO or COR will request a quote for the O&A action. Upon approval of the quote, the FAA COR will ensure sufficient funding is available on the O&A (a.k.a. Unscheduled Maintenance) CLIN.

If the contractor determines an O&A action is required, they must submit to the FAA

COR a description of the action, an explanation of why it is considered an O&A action, and a Not‐To‐ Exceed (NTE) price, as soon as practical. This must be done by electronic mail.

The COR will review the contractor O&A request with the appropriate FAA personnel and provide a recommendation of approval or disapproval to the CO. In addition, the COR will revalidate that sufficient funding is available on the O&A (or Unscheduled Maintenance) CLIN and provide this information to the CO. The CO will provide formal approval to the contractor via electronic mail or designate in writing the COR may provide this approval. Upon approval and completion of the O&A task the contractor must submit an invoice within thirty (30) days of receipt of goods or completion of services.

At a minimum, O&A actions or proposals must identify the requested maintenance or support action and specify the engine serial number, part number(s), tool, rental fee, etc.

with supporting pricing information (parts, labor, other fees). The contractor must provide a NTE or Firm-Fixed Price (FFP). Failure to agree on a reasonable price must be considered a question of fact subject to the DISPUTES clause of the contract.

Reasonable O&A parts handling markup/surcharge fees will be negotiated by FAA and contractor personnel prior to O&A authorization and must not exceed 10%. Shop fees are not authorized against O&A labor or parts.

8.0 TRAVEL FOR MEETINGS OR REVIEWS

Contractor travel costs for meetings or reviews, when determined necessary by the FAA will be in accordance with FAA Acquisition Management System (AMS) policies. Contractor travel associated with engine removal and installation must be included in the firm fixed price for the engine overhaul. All travel shall be authorized by the CO or COR prior to making travel arrangements. Travel is cost reimbursable and not authorized profit or overhead. Travel expenses shall be subject to the GSA per diem rates. The contractor shall provide supporting pricing documentation to support travel costs.

9.0 PERIOD OF PERFORMANCE

The first engine will be fully funded and scheduled for overhaul upon award. The period of performance to order additional engine overhauls on this stand-alone contract will be for two (2) years from the award date.

10.0 PLACE OF PERFORMANCE

The engine overhaul facility must be recognized by General Electric (GE) as a GE Engine Certified overhaul and repair facility. All engine removals and installs, unless otherwise instructed, will occur at the Mike Monroney Aeronautical Center in Oklahoma City, Oklahoma.