Attachment 3 - Statement of Work.pdf

ATTACHMENT 3

STATEMENT OF WORK

REPAIR AND OVERHAUL OF ENVIRONMENTAL CONTROLS

FOR HC-144 AIRCRAFT

1.0 BACKGROUND

1.1 The Coast Guard currently operates Eighteen (18) HC-144 Maritime Patrol Aircraft, each powered by two CT7-9C3 turboprop engines which use the model 14RF-37 Propeller. The aircraft is manufactured by AIRBUS MILITARY (formerly EADS CASA) in Seville, Spain. While the base CASA CN-235-300M MPSA aircraft provides the foundation for the Coast Guard HC-144, changes to the base aircraft configuration and the addition of supplementary systems have been combined resulting in a CG0l version of the CN-235-300M MPSA.

1.2 The Maritime Patrol & Surveillance Aircraft (MPSA) operate differently from general aviation in support of Coast Guard operations which consist of Search and Rescue, Surveillance, and Reconnaissance missions. Coast Guard HC-144 missions require frequent operation at lower altitudes and minimal/ unpressurized cabin conditions in salt-laden environments. This environment contributes to an increase of corrosion on airframe structures, engines and components of the aircraft.

2.0 SCOPE

2.1 To establish overhaul and repair services for the listed Hamilton Sundstrand Air Cycle Machine and air conditioning system components (listed in the solicitation schedule). This would include the complete teardown, inspection, rework, repair, assembly, and testing of all items identified in the Schedule IAW OEM specifications and/or other USCG approved Engineering Authorization.

This SOW establishes the minimum Coast Guard requirements necessary for overhaul and repairs, and is not intended to be all inclusive, nor detract from the procedures outlined in the manufacturer's drawings, manuals, specifications, action items and service bulletins. Coast Guard configuration control requires that applicable Service Bulletins and modifications for all ACMS tracked Hamilton Sundstrand components not previously configured, shall not be incorporated without prior written approval from the Coast Guard Contracting Officer.

3.0 REQUIREMENTS

3.1 The contractor shall be a certified Federal Aviation Administration (FAA) Part 145 authorized overhaul and repair center or equivalent to effectively inspect, test, troubleshoot, clean, overhaul, repair and preserve the listed Hamilton Sundstrand components within this scope and requirements; IAW the most current Hamilton Sundstrand or other OEM Component Maintenance Manuals (CMM), Action Items, revisions, temporary revisions, and specifications, including Service Bulletins, Service Information Release, amendments, and modifications. Maintain all Coast Guard specific requirements for return to service in a Ready for Issue condition and Coast Guard operational use. The Hamilton Sundstrand components shall be complete and configured for installation on Coast Guard HC-144 aircraft.

REPAIR AND OVERHAUL OF ENVIRONMENTAL CONTROLS

3.2 The Coast Guard does not own, nor can it provide access to or copies of OEM publications.

3.3 The Contractor shall be responsible for all necessary functions to perform the contracted services requested. This includes, but is not limited to, required tooling, manuals, test equipment, parts, material, engineering services, management, personnel, documentation, preservation, shipping, etc.

3.4 Designated Engineering Representative (DER) Repair Procedures

3.4.1 DER Repair procedures may be authorized on a case-by-case basis after review and approval by the Coast Guard Engineering Officer.

3.4.2 The Contractor shall submit a complete technical package to the Coast Guard Contracting Officer showing the DER repair procedure on a FAA form 8110-3 which shall meet the original OEM operational requirements. This information shall be treated as Procurement Sensitive and shall not be released to parties outside of the Government.

3.5 The Contractor shall track and document calendar time, flight time, flight/life cycles, for all work and services performed on the Hamilton Sundstrand components as required under Coast Guard ACMS. See Section 6.0 for specific information.

3.6 If the Contractor for any reason loses its FAA part 145 certification during the period of performance, this constitutes a material breach of contract which may, at the discretion of the Coast Guard Contracting Officer, result in contract termination. The Contractor shall notify the Contracting Officer verbally and in writing, not later than five (5) calendar days after certification forfeiture and disclose all facts relevant to the forfeiture.

3.7 The contractor shall ensure that all Action Items (AI), Service Bulletins (SBs), Amendments (AMDs) and Modifications (MODs) that have previously been incorporated remain incorporated unless otherwise appropriately superseded and directed by the Coast Guard Contracting Officer.

3.8 The contractor shall identify and recommend new or additional AIs, SBs, AMDs, or MODs, as applicable, to be incorporated and specify how the AIs, SBs, AMDs, or MODs may affect components, part numbers, and pricing. The Contractor shall contact the Coast Guard Contracting Officer, in writing, via FAX or e-mail for approval to incorporate the changes.

3.9 The contractor must be subscribed to receive notifications to all applicable OEM Hamilton Sundstrand or other OEM Manual publications: Component Maintenance Manuals (CMM), Action Item Log (AI), Revisions (Rev), Temporary Revisions (TR), Service Bulletins (SB), Service Information Release, Modifications (MOD), Amendments (AMD), including Contractor specifications and procedures applicable, to be used for the inspection, repairs or overhaul of the listed Coast Guard Hamilton Sundstrand components.

REPAIR AND OVERHAUL OF ENVIRONMENTAL CONTROLS

3.10 If the Contractor receives information more current than that previously provided to the Coast Guard, the Contractor shall identify the Hamilton Sundstrand or other OEM Manuals, CMMs, Ais, Revisions, and specifications, including Service Bulletins, Service Information Release, Amendments, and Modifications, and provide a brief synopsis of the revisions and dates to the Coast Guard's Contracting Officer for review and disposition approval.

3.11 Environmental Requirements

3.11.1 All parts must be thoroughly cleaned IAW applicable Component

Maintenance Manuals to ensure they are as free as practicable of all hazardous dust to include hexavalent chromium, cadmium, lead, etc., prior to being returned to ALC. ALC may take random samples of parts to ensure they are free as practicable of all hazards. Information on these hazards can be found in Occupational Safety and Health Standards 1910.1025 (lead), 1910.1026 (Hexavalent Chromium) and

1910.1027 (Cadmium)

3.12 Provide written delivery order receipts within 5 working days for all Hamilton Sundstrand components.

3.12.1 Delivery order receipts shal1 include, but are not limited to, the following information: nomenclature, National Stock Numbers (NSN), P/Ns, S/Ns, contract number, delivery order numbers, Contract Line- Item Numbers (CLIN), and dates of receipt.

3.12.2 Delivery order receipts via facsimile/email are acceptable and may contain single or multiple notification entries.

3.13 To maintain all Service Bulletins (Mandatory and Optional), and Action Items, (Public and Private) and other modifications previously incorporated unless otherwise directed by the Coast Guard Contracting Officer.

3.13.1 Service Bulletins and Action Item configurations are subject to change during the course of the contract period. Service Bulletins, Action Items, and modifications not previously incorporated shall be identified in writing to Coast Guard Contracting Officer.

3.13.2 Within 30 calendar days of OEM publication, the Contractor shall obtain and notify the Coast Guard Contracting Officer of any new Service Bulletin or Action Item for disposition approval prior to incorporation. Coast Guard HC-144 Engineering Officer or designated representative shall approve all newly published Service Bulletins and/or Action Items.

3.13.3 Service Bulletins and Action Items incorporated during performance of this requirement may create new part number configurations, which supersede the previous configurations. In cases where the older configurations cannot be modified to the newer configurations, the new configuration part numbers may be added to the contract. The Contractor shall notify and request disposition instructions from the Coast Guard Contracting Officer for superseded parts, which have

REPAIR AND OVERHAUL OF ENVIRONMENTAL CONTROLS

been removed and replaced by newer configurations.

3.13.4 Upon receipt of notification from the OEM that a Service Bulletin, Action Item, or modification is published, the Contractor shall notify and submit, within ten (10) calendar days after receipt of that notification, a firm-fixed price proposal for the Service Bulletin or Action Item to be incorporated in the component to the USCG. The proposal shall contain a breakdown of material and labor costs including hours, labor categories, labor rates, and applicable mark ups. Upon completion of negotiations, a contract modification will be issued to reflect the change, and the service bulletin shall be incorporated into each subsequent component received at the Contractor's facility for which the service bulletin has not already been incorporated. When Service Bulletin or Action Item incorporation changes the Contract Line Item Number (CLIN) part number, the new part number shall be added to the contract. The same procedures apply if removal of service bulletins is required. Failure to supply a change notice shall forfeit the right to any increase as a result of the contractor's failure to request a price change.

Unless the contractor has a signed contract modification permitting a change and bearing the signature of a Coast Guard Contracting Officer, funding has not been authorized. Performance without written authority from the Coast Guard Contracting Officer will not be authorized for payment.

3.14 Prepare and submit, component Teardown Inspection Reports (TIR)

3.14.1 TIRs, are occasionally requested by the Coast Guard Contracting Officer, and are usually requested in support of a Coast Guard Engineering incident, safety investigation, warranty determination, or for other failure analysis.

3.14.2 Upon request, the Contractor shall within ten calendar days provide a copy of the TIR to the Contracting Officer. TIRs, when requested, shall be forwarded to the Coast Guard Contracting Officer prior to commencement of repair or overhaul work.

3.14.3 TIRs shall include: nomenclature, NSNs, P/Ns, S/Ns, Contract number, Delivery Order numbers, CLINs, including descriptions, photos, illustrations, and drawings, as necessary before and during teardown, for documentation of the failure, and list all parts and costs as would be required for repair/overhaul of the component or assembly. The TIR shall also list all tolerances, and/or specification(s) which are out of limits to include CMM reference and the exact location on the component with the associated discrepancy measurements.

3.15 Replacement Parts:

3.15.1 Contractor is responsible for all replacement parts required for repairs/overhauls, including high time, life, or cycle limited parts.

REPAIR AND OVERHAUL OF ENVIRONMENTAL CONTROLS

3.15.2 Replacement parts shall be new and have full traceability to the OEM, Hamilton Sundstrand. See Paragraph 3.15.3 concerning PMA parts (Parts Manufacturer Approval).

3.15.3 Parts Manufacturer Approval (PMA)

3.15.3.1 PMA parts may be authorized on a case-by-case basis after review of technical documentation and approval by Coast Guard Engineering Officer.

3.15.3.2 A PMA parts list may be proposed by the contractor to include supporting rational of the PMA recommendations with all PMA certification documentation.

3.15.3.3 The contractor shall submit a complete technical package to the Coast Guard contracting officer showing that the PMA part meets or exceeds the original OEM specifications. This information will be treated as proprietary information; the Coast Guard will not release this information to other sources outside of the Government.

3.15.4 Defective parts: The cost of repair or replacement of defective parts is inclusive to the component repair contract price. Defective parts which cannot otherwise be repaired IAW OEM specifications, shall be reported to the Inventory Manager (IM) and labeled as scrap. The IM shall provide directions for all scrapped parts.

3.16 Beyond Economical Repair (BER):

3.16.1 When the cost of returning the contract line item (CLIN) part to serviceable condition exceeds the current replacement cost of that part;

or when the part cannot be repaired or overhauled due to damage or wear beyond the material properties, characteristic, or specifications of the item, the following procedures shall apply. The Contractor shall contact the Coast Guard Contracting Officer, in writing, via FAX or e-mail, with specific rationale for the BER condition. The rationale shall include and provide: Teardown Inspection Report, nomenclature, NSN, P/N, S/N, contract number, delivery order number, and CLIN along with a cost breakdown of additional parts and labor as would be necessary to repair the component to serviceable status.

3.16.2 If the contract line item (received at the Contractor's facility) is later determined to be in a BER condition. The Coast Guard Contracting Officer shall be notified immediately following the BER determination and provide rational.

3.16.3 Once the contract line item is determined to be BER, no further repair/overhaul work on that item shall be performed and the item in question shall be placed in a bonded storage room for safekeeping until written authorization to proceed or other disposition instructions are received from the Coast Guard Contracting Officer.

REPAIR AND OVERHAUL OF ENVIRONMENTAL CONTROLS

3.17 Missing or Cannibalized Components

3.17.1 Missing Components: Within ten (10) working days after the receipt and inspection of the components the Contractor shall notify the Coast Guard Contracting Officer in writing of any missing parts or sub-assemblies required for final inspection and acceptance. The Coast Guard Contracting Officer will then have forty-five(45) calendar days to provide formal disposition instructions to the Contractor. The Coast Guard reserves the right to provide Ready For Issue or repairable parts to replace the missing parts.

3.17.2 Cannibalized Components: Upon receiving components exhibiting cannibalization, the Contractor shall notify the Coast Guard Contracting Officer, in writing and in detail, within ten (10) working days and discontinue all actions until receipt of written authorization to proceed from the Coast Guard Contracting Officer. The Coast Guard Contracting Officer reserves the right to appoint a Coast Guard Representative who shall witness the remaining teardown and inspection of the component. A letter of notification and a Teardown Inspection Report (TIR) shall be submitted to the Contracting Officer for disposition.

3.17.3 Turn-Around-Time (TAT) stops as of the date on the

correspondence giving notification that work must cease due to missing/cannibalized parts. Unless the Coast Guard Contracting Officer elects to have the component returned to the Coast Guard as is, the TAT will re-start effective as of the mutually agreeable date stated in the bilateral modification.

3.18 Corrosion

3.18.1 Minimal cabin pressurization, non-ram air cooling design and low altitude flight over salt water contributes to greater wear and corrosion damage in Coast Guard components than that experienced in commercial aircraft air conditioning system components. The Contractor shall consider the presence these conditions and effects of corrosion to be "normal" in this case and provide for correction and removal of corrosion in the firm fixed repair/overhaul price. During inspection and functional testing, the presence of corrosion in an item or part thereof shall constitute reason for a more thorough disassembly and inspection.

3.18.2 Corroded parts shall be replaced, except in those cases where removal of corrosion from a part will not impair the efficiency or safe operation of the part. Corrosion removal and treatment of any affected areas shall be accomplished IAW the applicable CMM repair procedures.

3.19 Exclusions: Components received in the following conditions are to be considered exclusions and may indicate an exclusion from the price in the contract schedule:

REPAIR AND OVERHAUL OF ENVIRONMENTAL CONTROLS

3.19.1 Catastrophic crash damage, foreign object damage, domestic object damage traceable to a Coast Guard documented repair on the Hamilton Sundstrand components, Acts of God, war, and accidents attributable to the Coast Guard responsibility.

3.19.2 Alteration, modification or repairs that were not completed by the Coast Guard IAW technical data approved by the FAA, OEM, or the Coast Guard.

3.19.3 If a component is considered (by the Contractor) to fit the exclusion description, the Contractor shall notify the Coast Guard Contracting Officer within IO working days and discontinue all actions until the Contracting Officer makes a determination. The Coast Guard reserves the right to appoint a Coast Guard Representative to witness the remaining teardown and inspection of the component. A letter of notification and the Teardown Inspection Report (TIR) shall be submitted to the Coast Guard Contracting Officer for disposition of the component. The Contractor shall make the affected equipment available to a Coast Guard Representative to view the exclusionary damage. If the Government elects not to physically view the equipment, the Contractor's findings report shall stand.

3.19.4 Upon request by the Coast Guard's Contracting Officer, the Contractor shall submit a firm fixed price to include an itemized breakdown of material including nomenclature, part number, cost, and quantity of replacement parts, replacement percentages used to develop the original firm fixed contract price and the number of labor hours at the labor rates proposal for additional funding required to restore exclusionary damage. This proposal shall include all necessary supporting rationale and shall be submitted within forty-five (45) calendar days after notification is given to the Coast Guard Contracting Officer. Upon completion of negotiations, the Coast Guard Contracting Officer may authorize repair/overhaul, via contract modification.

4.0 APPLICABLE DOCUMENTS

4.1 All Hamilton Sundstrand Component Maintenance Manuals (CMMs), CMM Action Item Log (Als), Revisions, modifications, and Service Bulletins and Service Information Reports as applicable to the Hamilton Sundstrand components. Applicable publications have been identified in paragraph 4.1 but not limited to as other OEM applicable documentation or specifications revealed, published, or updated prior to award or during the course of the contract period, shall be considered as being within the scope of this requirement and may be added to the contract as agreed upon by both parties.

4.2 All other OEM Component Maintenance Manuals (CMMs) and Revisions as applicable to the Hamilton Sundstrand components.

REPAIR AND OVERHAUL OF ENVIRONMENTAL CONTROLS

4.3 Hamilton Sundstrand and other OEM CMMs, Revisions, Service Bulletins, Modifications, Amendments, and Specifications are proprietary; the Coast Guard does not own or possess rights in data, or distribution authority, and they cannot be provided by the Coast Guard.

4.4 USCG technical documents and/or procedures may be referenced and provided to support specific requirements mandated for sustainment of the HC-144. Where cited the contractor shall document compliance with the requirements on the 8130-3 or COC respectively.

4.5 Sustainment of certain critical supply components has been allowed/supported via proprietary repair procedures authorized by the USCG. Sustainment of non-repairable components relies on the associated intellectual repair data and shall be implemented as required during repairs.

5.0 DEFINITIONS

5.1 Asset Computerized Maintenance System (ACMS) tracking provides an effective means of configuration control to maintain the integrity of OEM overhaul/high time hourly intervals including flight and life cycle limits as applicable to Hamilton Sundstrand components. See section 6.0 for specific information on the incorporation of Coast Guard ACMS requirements.

5.2 Time Since Overhaul (TSO) shall be zeroed after an overhaul and may effectively restart some sub-assembly time intervals; while the total time, and OEM component life cycle limits may continue as applicable.

5.3 Modification(MOD) is defined as the incorporation of FAA approved Service Bulletins, Spare Parts Bulletins, and Airworthiness Directives. This also includes Coast Guard Time Compliance Technical Order (TCTO), and Special Compliance Technical Orders (SCTO), that are based on the FAA approved documents listed above. See paragraph 3.17 for incorporation of Service Bulletins and modifications.

5.4 Beyond Economical Repair (BER): When the cost of returning the component to serviceable condition, exceeds the current replacement cost of that component, or when the component cannot be repaired or overhauled due to damage or wear beyond the material properties, characteristic, or specifications of the item. See paragraph 3.20 for specific information on Coast Guard BER requirements.

5.5 Service bulletin (Mandatory and Optional): An Official statement from the OEM to correct issues or improve efficiency of systems within the aircraft.

The Contractor shall be responsible for obtaining and notifying the Coast Guard Contracting Officer of all service bulletin changes and modifications, for disposition approval prior to incorporation of those changes and modifications. See paragraph 3.17 for incorporation of Service Bulletins and modification.

REPAIR AND OVERHAUL OF ENVIRONMENTAL CONTROLS

6.0 COAST GUARD ASSET COMPUTERIZED MAINTENANCE SYSTEM

(ACMS) REQUIREMENTS

6.1 The contractor shall comply with all Coast Guard ACMS documentation requirements.

6.1.1 Some Hamilton Sundstrand components are serial number tracked under

Coast Guard ACMS. This tracking provides historical records of repairs, modifications, overhauls, flight times, cycles, item location, status, and an effective method of configuration control. Components that are serial number tracked under Coast Guard ACMS should, at the time of receipt, have a blank Component Repair Record (CRR), and a current Significant Component History Report (SCHR) attached to the component.

6.1.2 For configuration control, prior written approval of the Coast Guard Contracting Officer shall be obtained for any configuration changes to Hamilton Sundstrand components. See paragraph 2.1, 3.14 and 3.17 for specific information on the incorporation of Service Bulletins and modifications.

6.1.3 Verify the SCHR and CRR correspond with the NSN, P/N, and S/N of the component received. Promptly report discrepancies to the Coast Guard Contracting Officer prior to performing any work.

6.2 Complete the Component Repair Record or a Contractor proposed form pre-approved by the Coast Guard, describing the work performed, the technical data used to perform the work, and any significant parts replaced.

6.2.1 The CRR shall provide a complete description of the work performed, the component status (repaired, modified, overhauled, BER, scrap, etc.)

and include, but not be limited to: the Contract number, Delivery Order number, CLIN, the Contractor's Work Order number, the date work was completed, any changes to the TSO, and total time, landings, or cycles as applicable.

6.2.2 The information provided in the CRR will be used by the Coast Guard to update the component SCHRs.

6.3 Provide two copies of the completed CRR as follows:

6.3.1 One copy of the CRR shall remain with the material and is to be returned with the component upon completion of the repair modification or overhaul.

6.3.2 A second copy of the CRR shall be mailed to:

USCG, AVIATION LOGISTICS CENTER

ATTN: ACMS

1664 WEEKSVILLE ROAD, BLDG. 63

ELIZABETH CITY, NC 27909-5001

REPAIR AND OVERHAUL OF ENVIRONMENTAL CONTROLS

6.3.3 The CRR is considered a deliverable under the contract, and noncompliance with instructions will result in the delay or nonpayment of the invoice.

6.4 Provide one copy of an approved FAA Airworthiness Fonn 8130-3 or other

FAA authorized form (e.g. EASA Form 1).

6.4.l Attach one copy to the component along with the CRR.

6.4.2 The FAA airworthiness Fonn 8130-3, the OEM Certificate of Conformance or a Certificate of Conformance IAW FAR 52.246-15 is considered a deliverable under the contract, and noncompliance with instructions herein, will result in the delay or nonpayment of the invoice.

7.0 MARKING, PACKAGING, AND PRESERVATION

7.1 All containers must be labeled on the outside with the National Stock Number (NSN), P/N, S/N, nomenclature, contract number, delivery order number, Contract Line Item Number (CLIN), and vendor CAGE Code.

7.2 The internal packaging material shall be sufficient to prevent damage during shipment, handling, and storage. Preservation protection must be sufficient to prevent corrosion, deterioration or decay during warehouse storage for a period of not less than one year.

7.3 Packaging matter shall not consist of the following materials: popcorn, shredded paper, Styrofoam or any type of peanut packaging.

7.4 Bar coding is authorized but not required.

8.0 INSPECTION AND ACCEPTANCE

8.1 Notwithstanding any requirement for specific inspections to be performed solely by the Government, the Contractor shall perform all inspections, tests, and checks as required to substantiate that the supplies and services provided under the contract conform to the latest drawings, specifications, CMMs, and contract requirements listed herein.

8.2 Final inspection and acceptance shall be performed by ALC quality assurance personnel for quantity, condition, and compliance with the contract statement of work.

ATTACHMENT

OVERHAUL AND REPAIR OF ENVIRONMENTAL CONTROL COMPONENTS

9.0 ACRONYMS

ACMS Asset Computerized Maintenance System

AI Action Item

ALC Aviation Logistics Center

AMD Amendment

AOG Aircraft-On-Ground

ARM After Receipt of Material

ASSY Assembly

BER Beyond Economical Repair

CLIN Contract Line-Item Number

CMM Component Maintenance Manual

CPC Corrosion Preventative Compound

CRR Component Repair Record

DCMA Defense Contract Management Agency

DER Designated Engineering Representative

FAA Federal Aviation Administration FOD Foreign Object Damage

GFP Government Furnished Property

IAW In Accordance With

IPC Illustrated Parts Catalog

MOD Modification

MPSA Maritime Patrol & Surveillance Aircraft

NSN National Stock Number

OEM Original Equipment Manufacturer

PMA Parts Manufacturer Approval P/N Part Number

REV Revision

RFI Ready For Issue

SB Service Bulletin SCHR Significant Component History Report

ATTACHMENT

OVERHAUL AND REPAIR OF ENVIRONMENTAL CONTROL COMPONENTS

SIR Service Information Release

S/N Serial Number

SOW Statement Of Work TAT Turn Around Time

TIR Teardown Inspection Report TR Temporary Revision

TSN Time Since New TSO Time Since Overhaul USCG United States Coast Guard

END OF STATEMENT OF WORK