Appendix A-SOW CERP Engine Contract.pdf

B-52H

Commercial Engine Replacement Program

Engine Contract

Contract #: FXXXX-XX-X-XXXX

STATEMENT OF WORK

Period of Performance

18 May 2020

Prepared by

B-52 Program Office Air Force Life Cycle Management Center

Tinker Air Force Base

Oklahoma City, OK 73145

TABLE OF CONTENTS

1 Introduction

1.1 Background

1.2 Purpose

1.3 Scope

1.4 Period and Place of Performance

2 Applicable Documents

2.1 Military Standards

2.2 Other Organization Documents

2.3 Other Government Documents

3 Engine

3.1 Commercial Engine Replacement Program (CERP) Engine

3.1.1 Engine Configuration

3.1.1.1 CERP Engine (Rapid Prototype)

3.1.1.1.1 Non-Recurring Engineering (NRE) for Rapid Prototype Engine

3.1.1.1.1.1 CERP Instrumented Prototype Engines

3.1.1.1.1.2 System Requirements Review (SRR)

3.1.1.1.1.3 Preliminary Design Review (PDR)

3.1.1.1.1.4 Critical Design Review (CDR)

3.1.1.1.1.5 Test Readiness Review (TRR)

3.1.1.1.1.6 Test Support

3.1.1.2 CERP Engine (Production Engine)

3.1.1.2.1 NRE for Production Engine

3.1.1.3 Commercial Spare Parts Price List (CSPPL)

3.1.1.3.1 Spare Parts

3.1.2 Shipping

3.1.2.1 Special Packaging Instructions (SPI)

3.1.2.2 Significant Historical Data

3.1.3 Lifecycle Analysis

3.1.4 Integration

4 Program Management

4.1 Contractor Program Manager (CPM)

4.1.1 Program Management Plan

4.1.2 Risk Management Plan

4.1.3 Risk/Issue/Opportunity (RIO) Management Plan (RIOMP)

4.1.4 Risk Management Status Report

4.2 Contractor Team Description

4.3 Contract Management

4.3.1 Monthly Status Report (MSR)

4.3.2 Program Reviews

4.3.2.1 Program Management Reviews (PMRs)

4.3.2.2 User’s Conference/Maintenance Planning Working Group (MPWG)

4.3.3 Associated Contractor Agreement (ACA)

4.3.4 Leading Health Indicators (LHI)

4.4 Engineering

4.4.1 Engineering Drawings/Models

4.4.2 Sustaining Engineering Support

4.4.2.1 Technical Assistance Request (TAR)/Maintenance Assistance Request (MAR)

4.4.2.1.1 Immediate Request

4.4.2.1.2 Urgent Request

4.4.2.1.3 Routine Request

4.4.3 Propulsion System Integrity Program (PSIP) Master Plan

4.4.4 Engine Trending and Diagnostics (ET&D)

4.4.5 Engineering Studies

4.4.5.1 Verification and Validation Plan/Report

4.4.6 Lead-the-Fleet/Analytical Condition Inspection (LtF/ACI)

4.4.6.1 Analytical Condition Inspection (ACI) Plan

4.4.6.2 ACI

4.4.6.3 ACI Report

4.4.7 Accelerated Mission Test (AMT)

4.4.7.1 AMT Plan

4.4.7.2 AMT

4.4.7.3 AMT Report

4.4.8 Engine Cycle Deck and User’s Guide

4.4.9 Verification Matrix

4.4.9.1 Verification Matrix Report

4.4.10 Test Plan

4.4.10.1 Engine Development Plan Presentation

4.4.11 Test/Inspection Reports

4.4.12 Software Design Description (SDD)

4.4.13 Software Version Description (SVD)

4.4.14 Airworthiness Certification

4.4.14.1 Airworthiness Certification Requirements for Multi-Core Processors

4.4.14.2 Airworthiness Certification Plan

4.4.15 Airworthiness Specification

4.4.15.1 Airworthiness Certification Basis

4.4.16 Airworthiness Certification Criteria Report

4.4.17 Control Logic, Lifing & Trending

4.4.18 Software Development Integrity Master Plan (SDIMP)

4.4.19 Software Requirements Specification (SRS)

4.4.20 Software Test Plan (STP)

4.4.21 Software Test Description (STD)

4.4.22 Software Test Report (STR)

4.5 Configuration Management

4.5.1 Engine Configuration Management

4.5.2 Configuration Management Plan (CMP)

4.5.3 Configuration Control

4.5.4 Engineering Change Proposal (ECP)

4.5.4.1 Request for Deviation

4.5.4.2 Notice of Revision (NOR)

4.5.5 EPS Change Process

4.6 Logistics

4.6.1 Reliability and Maintainability (R&M)

4.6.2 Counterfeit Parts

4.6.3 Provisioning List

4.6.3.1 Line Replaceable Unit (LRU) Spares Requirements

4.6.3.2 Parts Usage and Maintenance Data Collection

4.6.4 Diminishing Manufacturing Sources & Material Shortages (DMSMS) Planning

4.6.5 Identification Markings

4.6.6 Production Records Retention

4.6.7 Comprehensive Engine Management System (CEMS)

4.6.8 Lifing Analysis

4.6.9 Engine Life Management Plan (ELMP)

4.7 Disposal and Demilitarization

4.7.1 Precious Metals and Critical Alloys

4.7.2 Disposal and Demilitarization

4.8 Quality

4.8.1 Quality Management System (QMS)

4.8.2 Quality Management Plan

4.8.3 QMS Reporting

4.8.4 Deficiency Reports (DRs)

4.9 Safety

4.9.1 System Safety Program Plan (SSPP)

4.9.2 System Safety Working Group

4.9.3 Failure Modes, Effects, and Criticality Analysis (FMECA)

4.9.4 Safety Risk Assessment

4.9.5 Safety Reports

4.9.6 Safety Investigation Board (SIB) and Accident Investigation Board (AIB) Support

4.9.7 System Safety Hazard Analysis (SSHA) Report

4.9.8 Safety Assessment Report (SAR)

4.10 Field Service Representatives (FSR)

4.11 Travel

4.12 Security Requirements

4.12.1 Program Security Change

4.13 Operational Security (OPSEC) Plan

4.14 Cybersecurity

4.14.1 Cybersecurity Assessments

4.14.2 Penetration Testing at Contractor Facility

4.14.3 Penetration Testing at Government Designated Facility

4.14.4 Cyber Incidents

4.14.5 Criticality Analysis

4.14.6 Architecture Design

4.15 Program Security

5 Data

5.1 Technical Support Data

5.2 Technical Order Distribution Office (TODO)

5.3 Service Compliance Publications

5.4 Maintenance and Operation Data

5.4.1 Instructions for Continued Airworthiness (ICA)

5.4.2 Bill of Material (BOM)

5.5 Long-Term Commercial Repair Supportability

5.6 Depot Maintenance and Operations

5.6.1 Depot Maintenance and Operations (Separately Priced Data)

5.6.2 Depot Level Parts Provisioning (Separately Priced Data)

5.6.2.1 Provisioning Technical Documentation (PTD)

5.6.2.2 Engineering Data for Provisioning (EDFP)

5.6.2.3 Provisioning Conferences (TBN)

5.6.2.3.1 Provisioning Guidance Conference (PGC)

5.6.2.3.2 Spares Provisioning Conference

5.7 Data Accession List (DAL)

5.8 Data (TBN Per Occurrence)

6 Tooling, Support/Test Equipment, and Hand Tools

6.1 Support Equipment Recommendation Data (SERD)

6.2 Support/Test Equipment/Tooling

6.3 Transportation/Miscellaneous Shipping

7 Maintenance

7.1 Teardown and Inspection Report

7.2 Per Event Repair

7.2.1 Engine Repair

7.2.1.1 Repair Labor Maintenance

7.2.1.2 Repair Labor Engineering

7.2.1.3 Repair Materials

7.2.1.4 Trailer and Other Associated Equipment

7.2.2 Non-Conforming Material

7.2.3 Parts Usage and Maintenance Data Collection Report

7.2.4 LRU Repair

7.2.5 Shipping of Repaired Assets

7.3 Contract Field Team (CFT) Support

7.3.1 Maintenance

7.3.1.1 Contractor Field Team (CFT) Support Maintenance

7.3.1.2 CFT Support Engineering

8 Training

9 Deliverables

10 Common Access Card (CAC)

11 Over and Above (O&A)

11.1 Transportation/Miscellaneous Shipping

11.2 Travel

11.3 Maintenance for O&A

11.4 Material for O&A

LIST OF ATTACHMENTS

Acronym List .......................................................................................................... Attachment A

B-52H CERP Risk/Issue/Opportunity Management Plan ...................................... Attachment B

Certification Basis ................................................................................................... Attachment C

Non-Recurring Engineering Exclusion List ............................................................ Attachment D

Manual Requirements ............................................................................................. Attachment E

Illustrated Parts Catalog/Illustrated Parts Breakdown ............................................ Attachment F

B-52 A-H Weapons System Program Security Classification Guide ..................... Attachment G

Director of Propulsion Engine Life Management Plan Template .......................... Attachment H

Accelerated Mission Test Engine Plan ................................................................... Attachment J

Accelerated Mission Test Engine Report ............................................................... Attachment K

Safety Report .......................................................................................................... Attachment L

Workscope Requirements ....................................................................................... Attachment M

Shop Visit Report .................................................................................................... Attachment N

Firm Fixed Price Inspection and Repair Requirements .......................................... Attachment O

Leading Health Indicators Checklist Questionnaire ............................................... Attachment P

Guidance for Propulsion System Integrity Program Master Plan ........................... Attachment Q

Provisioning Technical Documentation Requirements .......................................... Attachment R

Engineering Data for Provisioning ........................................................................ Attachment S

Engine Procurement Specification, B-52H CERP .................................................. Attachment V

Propulsion Center of Excellence Best Practice, Aircraft Gas Turbine Engine

Flight Safety Risk Management Process ................................................................ Attachment X

Comprehensive Engine Management System Requirements .................................. Attachment Y

Trip Report Template .............................................................................................. Attachment Z

USAF CyberSecurity Classification/Declassification Guide for Air Force

Weapon Systems ............................................................................................... Attachment AA

Air Force Anti-Tamper Security Classification Guide ......................................... Attachment AB

Technical Review Entrance and Exit Criteria ...................................................... Attachment AC

Guidance for Multi-Core Processor Use .............................................................. Attachment AD

Draft Propulsion System Interface Control Document ......................................... Attachment AE

Draft Engine Master Measurement List ................................................................ Attachment AF

1 Introduction

1.1 Background

The B-52H’s existing TF33-PW-103 engines have been on the aircraft since the early 1960s.

The weapon system’s projected airframe life is slated through 2050. The Commercial Engine

Replacement Program (CERP) is needed in order to extend the life of the B-52H until the weapon system’s proposed retirement date.

1.2 Purpose

This Statement of Work (SOW) sets forth the tasks required for the Contractor to supply engines configured for B-52H aircraft. The new CERP engines will replace legacy TF33-PW-

103 engines with primarily commercial/Non-Developmental Item (NDI) components.

The B-52H CERP’s mission is to replace the existing TF33-PW-103 engines with a military specific derivative of an existing commercial engine and achieve the overarching KSAs of the

B-52H CERP effort. In order to successfully integrate with the B-52H aircraft, this military-specific commercial derivative engine shall meet the mandatory requirements of the B-52H

CERP Engine Procurement Specification (EPS) and Propulsion System Interface Control

Document (ICD). The following three tables include mandatory EPS requirements from which deviations cannot be made, including the minimum requirements for Combat Ceiling and Take

Off Rated Thrust. The “shall” requirements contained within the EPS, but not identified in

Table 1-1, are still considered required. However, any deviations are subject to approval by the

Procuring Activity.

Table 1-1: Engine Procurement Specification Mandatory Requirements

Title Engine Requirement

(EPS Section/Table)

Fuel Efficiency (Key System Attribute

(KSA))

Sections 7.2.1.1.6 and 7.2.1.1.7

Electrical Power Generation (KSA) Section 7.2.4.2.12

Nuclear Hardening (KSA) Section 4.1.5.17 and 4.1.5.18

Scheduled Engine Removals Section 16.4.2

Unscheduled Engine Removal (UER) Rate Section 16.4.3

Table 1-2: Combat Ceiling Mandatory Requirements

Altitude(ft) Mach Ambient

Temperature (°F) Engine Thrust

Setting Thrust (lbf)

39,000 0.76 -69.7 MRT 3,726

Table 1-3: Takeoff Rated Thrust Mandatory Requirements

Altitude(ft) Mach Ambient

Temperature (°F) Engine Thrust

Setting Thrust (lbf)

0 0.0 59.00 TRT 16,361

0 0.15 59.00 TRT 14,439

0 0.3 59.00 TRT 13,078

1,500 0.0 53.65 TRT 15,730

1,500 0.15 53.65 TRT 13,959

1,500 0.3 53.65 TRT 12,716

6,000 0.3 37.60 TRT 11,627

0 0.0 114.8 TRT 13,835

0 0.15 114.8 TRT 11,581

0 0.3 114.8 TRT 10,107

1,500 0.0 108.2 TRT 13,571

1,500 0.15 108.2 TRT 11,495

1,500 0.3 108.2 TRT 10,047

6,000 0.3 83.99 TRT 9,576

0 0.0 −40.00 TRT 16,361

0 0.15 −40.00 TRT 14,439

0 0.3 −40.00 TRT 13,078

1,500 0.0 −40.00 TRT 15,730

1,500 0.15 −40.00 TRT 13,959

1,500 0.3 −40.00 TRT 12,716

6,000 0.3 −40.00 TRT 11,627

0 0.0 140.0 TRT 11,764

0 0.15 140.0 TRT 9,489

0 0.3 140.0 TRT 7,955

1,500 0.0 134.7 TRT 11,561

1,500 0.15 134.7 TRT 9,391

1,500 0.3 134.7 TRT 7,937

6,000 0.3 118.6 TRT 7,857

The Government intends to maintain as much commonality with the commercially available engine while ensuring safe operation of the B-52H. More specifically, it is not the

Government’s intent to drive turbomachinery hardware redesign in order to comply with military unique requirements. The technical proposal shall identify differences or gaps of the proposed engine with the EPS and associated risks (including the supporting documentation).

In addition, the proposal will establish the path to obtain a Propulsion Military Type

Certification (P-MTC), which will be incorporated into the resultant contract.

1.3 Scope

This contract will be for the purchase of approximately 608 engines plus spares to be used for

B-52H CERP aircraft modification. The engine will be a military-modified commercial engine configured for operation in a military environment on a B-52H aircraft, hereinafter referred to as the “CERP Engine.” The physical and functional requirements for the CERP Engine are defined in SOW Attachment V, Engine Procurement Specification B-52H CERP.

The Contractor shall perform Non-Recurring Engineering (NRE) to achieve a CERP Engine configuration In Accordance With (IAW) the EPS.

This contract includes production and delivery of the CERP Engine as well as limited sustainment and repair activities. The repair of the CERP Engines used during integration and test will be performed under a separate contract.

The Contractor shall provide support of CERP Engines used during B-52 integration and test activities occurring under a separate contract.

**Acronyms used in this SOW are defined upon initial use in the body of this document and are also provided in SOW Attachment A, Acronym List.

1.4 Period and Place of Performance

The Period of Performance for the basic contract is 17 years with one 6-year base, one 5-year option, and six 1-year options. The primary work location for this contract will be on the

Contractor’s premises and in the Contractor’s facilities. The B-52 Program Office located at

Tinker Air Force Base is the point of contact for B-52H CERP.

2 Applicable Documents

The following documents referenced below are part of this SOW. In the event of a conflict between the SOW and the documents referenced herein, the SOW shall be considered the prevailing requirement.

2.1 Military Standards

MIL-DTL-38807D, 17 Sep 2012

Amendment 2, 27 Mar 2020

Manuals, Technical – Illustrated Parts Breakdown

MIL-HDBK-61B, 7 Apr 2020 Configuration Management Guidance

MIL-HDBK-2097A, 2 Jun 1989

Revision A, 25 Jul 1997

Acquisition of Support Equipment and Associated Integrated

Logistics Support

MIL-STD-882E, 11 May 2012 System Safety

MIL-STD-2073-1E, 7 Jan 2011

Change 4, 22 Apr 2019 Standard Practice for Military Packaging

MIL-STD-3022, 28 Jan 2008

Change 1, 5 Apr 2012

Documentation of Verification, Validation, and Accreditation

(VV&A) for Models and Simulations

MIL-STD-3024

Change 2, 4 May 2018

Propulsion System Integrity Program

2.2 Other Organization Documents

ASME Y14.24-2012, 5 Apr 2013 American Society of Mechanical Engineers, Types and

Applications of Engineering Drawings: Engineering Drawing and

Related Documentation Practices

CNSSD No. 505, 26 Jul 2017 Committee on National Security Systems Directive No. 505, Supply Chain Risk Management

ISO 9001:2015(E), 15 Sep 2015 International Organization for Standardization, Quality

Management Systems – Requirements, Fifth Edition

NIST 800-53R4, Apr 2013

Revision 4, 22 Jan 2015

National Institute of Standards and Technology; Security and

Privacy Controls for Federal Information Systems and

Organizations

NIST SP 800-160, Nov 2019

Volume 2

Developing Cyber Resilient Systems: A Systems Security

Engineering Approach

NIST SP 800-161, Apr 2015 National Institute of Standards and Technology Special Publication

800-161, Supply Chain Risk Management Practices for Federal

Information Systems and Organizations

SAE AS5553, Apr 2009

Revision C, Mar 2019

Society of Automotive Engineers Aerospace Standard; Counterfeit

Electrical, Electronic, and Electromechanical (EEE) Parts;

Avoidance, Detection, Mitigation, and Disposition

SAE AS6081, Nov 2012 Society of Automotive Engineers Aerospace Standard; Fraudulent/

Counterfeit Electronic Parts: Avoidance, Detection, Mitigation, and

Disposition – Distributors

SAE AS6171, Oct 2016

Revision A, Apr 2018

Society of Automotive Engineers Aerospace Standard; Test

Methods, General Requirements, Suspect/Counterfeit, Electrical, Electronic, and Electromechanical Parts

SAE AS9100D, Sep 2016 Society of Automotive Engineers Aerospace Standard; Quality

Management System Aerospace Requirements

2.3 Other Government Documents

AC-17-01, 22 Mar 2017 Airworthiness Circular Verification Expectations for Select Section

15 Criteria AFI 17-101, 6 Feb 2020 Risk Management Framework (RMF) for Air Force Information

Technology (IT)

AFI 51-307, 18 Mar 2019 Aerospace and Ground Accident Investigations

AFI 61-201, 29 Jan 2016 Management of Scientific and Technical Information (STINFO)

AFI 91-202, 12 Mar 2020 The US Air Force Mishap Prevention Program AFI 91-202 AFMCSUP1, 17 May 2017 US Air Force Mishap Prevention Program, AFMC Supplement

AFI 91-204, 27 Apr 2018

With AFGM 2019-01, 30 Jul 2019

Safety Investigation and Hazard Reporting

AFMAN 20-116, 28 Aug 2017 Propulsion Life Cycle Management for Aerial Vehicle

AWB-002A (USAF), 17 May 2011 Airworthiness Planning

AWB-003A (USAF), 17 Jun 2011 Tailored Airworthiness Certification Criteria/Modification

Airworthiness Certification Criteria (TACC/MACC) Document

Approval Process

AWB-004A (USAF), 17 Jun 2011 Development of Airworthiness Certification Basis

AWB-005 (USAF), 27 Sep 2010 Tailored Airworthiness Certification Criteria/Modification

Airworthiness Certification Criteria (TACC/MACC) Document

Construction and Format

AWB-330A (USAF), 17 Apr 2018 Propulsion System Type Certification

CPI/CC Guide, 8 May 2018

Version 1.1 United States Air Force Combined Process Guide for Critical Program Information (CPI) and Critical Component (CC) Identification

DOD 5220.22-M, Feb 2006 National Industrial Security Program Operating Manual

DODD 5200.47E, 4 Sep 2015 Change 2, 31 Aug 2018

Anti-Tamper (AT)

DODI 4160.28, 7 Apr 2011 Change 2, 31 Aug 2018

DOD Demilitarization (DEMIL) Program

DODI 5200.39, 28 May 2015 Change 2, 15 Oct 2018

Critical Program Information (CPI) Identification and

Protection Within Research, Development, Test and

Evaluation (RTD&E)

DODI 5200.44, 5 Nov 2012

Change 3, 15 Oct 2018

Protection of Mission Critical Functions to Achieve

Trusted Systems and Networks

DODI 5200.48, 6 Mar 2020

Controlled Unclassified Information (CUI)

DODI 6055.07, 6 Jun 2011

Change 1, 31 Aug 2018 Mishap Notification, Investigation, Reporting, and Record

Keeping

DODI 8500.01, 14 Mar 2014 Change 1, 7 Oct 2019

Cybersecurity

DODI 8510.01, 12 Mar 2014 Change 2, 28 Jul 2017

Risk Management Framework (RFM) for DOD Information Technology (IT)

DODM 4160.21-V1, 22 Oct 2015

Change 3, 2 Oct 2019 Defense Materiel Disposition: Disposal Guidance and Procedures

GIDEP Operation Manual Government-Industry Data Exchange Program, www.gidep.org

JDRS Joint Deficiency Reporting System, www.jdrs.mil

MEARS Multi-User Engineering Change Proposal (ECP) Automated Review System (MEARS), https://mears.army.mil/(S(owlx1dbcs4cr4pqq2frsh0in))/default.asp x

Program Protection Plan Outline & Guidance, Jul 2011, Version 1.0

Program Protection Plan Outline & Guidance

USAF SSE Acquisition Guidebook, 9 Oct 2018, Version 1.4

USAF Systems Security Engineering (SSE) Acquisition Guidebook

TO 00-5-1, 15 Feb 2019 Air Force Technical Order System

TO 00-5-3, 15 Feb 2019

Air Force Technical Order Life Cycle Management

TO 00-20-1, 6 Sep 2019 Aerospace Equipment Maintenance Inspection, Documentation, Policies, and Procedures TO 00-25-107, 1 Oct 2015 Maintenance Assistance

TO 00-25-113, 15 Sep 2013 Conservation and Segregation of Critical Alloy and Precious

Metal Parts and Scrap

TO 00-25-254-1, 15 May 2019 Comprehensive Engine Management System Engine

Configuration, Status and TCTO Reporting Procedures TO 00-35D-54, 1 Sep 2015 USAF Deficiency Reporting, Investigation, and

Resolution

3 Engine

3.1 Commercial Engine Replacement Program (CERP) Engine

The Contractor shall deliver engines configured for installation and utilization on B-52H aircraft, conforming to the requirements specified in B-52H CERP EPS and the Propulsion

System ICD, consistent with the Purpose of this program (SOW paragraph 1.2) and with the airworthiness approach as described in SOW paragraphs 4.4.14 – 4.4.16. The B-52H CERP replacement engines shall be in active production with capability for continued active http://www.gidep.org/ http://www.gidep.org/ http://www.jdrs.mil/ https://mears.army.mil/(S(owlx1dbcs4cr4pqq2frsh0in))/default.aspx https://mears.army.mil/(S(owlx1dbcs4cr4pqq2frsh0in))/default.aspx production through 2034 with supportability beyond 2050. The B-52H CERP modification shall be comprised of all new production parts. Used, refurbished, overhauled, reclaimed, or surplus parts shall not be utilized.

3.1.1 Engine Configuration

The CERP Engine configuration consists of a turbofan engine and the following equipment:

a. Fuel delivery system downstream of the aircraft supply line/fuel pump interface

b. Engine mounted Full-Authority Digital Engine Control (FADEC) System (alternate nomenclature – Electronic Engine Control System (EECS))

c. Dual ignition system

d. Lubrication System

e. Engine accessory gearbox

f. Hydraulic Pump Accessory Drive Pad cover plate suitable for continuous Engine operation

g. Borescope access and inspection provisions

h. Electrical harnesses from the Engine Manufacturer-supplied components to the engine control system.

i. Equipment mounting provisions for Aircraft Integrator-supplied hardware

j. Electrical generator cooling system

k. Exhaust gas temperature measuring system

l. Ground handling mounts

m. Rotor speed measuring system

n. Core compartment ventilation system

o. Engine drain systems

p. Engine vibration accelerometers

q. Starter, interconnecting ducting, starter air valve (Aircraft/Engine interface)

r. Engine sensors required for Engine control (e.g. P2/T2, P-Static, etc.) which are mounted on Aircraft Integrator Supplied Hardware

s. Fan duct bifurcation (as applicable to integral fan duct Engine configuration)

t. Fan duct sleeve integral to the engine configuration

u. Fan duct bifurcation sealing surface (as applicable to separate flow nacelle Engine configuration)

v. Inner fan duct extension ring (as applicable to separate flow nacelle Engine configuration) including interface to fan duct cowl

w. Primary core engine exhaust system consisting of: nozzle or mixer; plug; and center vent tube (as applicable).

3.1.1.1 CERP Engine (Rapid Prototype)

The Contractor shall develop and deliver CERP Engines (Rapid Prototype) suitable for installation onto B-52H aircraft conforming with the requirements in the EPS and the

Propulsion System ICD, consistent with the Purpose of this program (SOW paragraph

1.2) and with the airworthiness approach as described in paragraphs SOW 4.4.14 -

4.4.16. A draft Propulsion System ICD has been attached as SOW Attachment AE. The finalized Propulsion System ICD will be developed on a separate integration contract between the Contractor, integrator and the Government.

The CERP Engines (Rapid Prototype) shall be capable of achieving a Military Flight

Release (MFR) if a P-MTC has not been achieved at time of delivery. This rapid prototype configuration shall become the initial baseline configuration for the CERP

Engine. The Contractor shall conduct monthly technical reviews until delivery of the first production engine. The Contractor may recommend types of reviews as well as the format and agenda based upon mutual agreement by the Contractor and the Government.

(Contract Data Requirements List (CDRL) A004, DI-ADMN-81250B, Conference

Minutes)

The Contractor shall deliver CERP Engines (Rapid Prototype) within 18 months of delivery order issuance. The Contractor shall deliver the CERP Engines (Rapid

Prototype) to be utilized for initial B-52 CERP integration and test activities within 36 months from contract award via delivery order anticipated to occur approximately 18 months from contract award.

The Contractor shall perform acceptance testing to verify takeoff and cruise thrust (sea level static only), engine operability (stall margin and engine response, sea level static only), engine weight and center of gravity, lubrication and fuel system functionality, customer energy extraction (horsepower and bleed), and vibration levels meet EPS and

Propulsion System ICD specifications prior to delivery of a Rapid Prototype Engine. All acceptance test records shall be provided to Defense Contract Management Agency

(DCMA) prior to DD Form 250 signature and engine acceptance.

The Contractor shall perform NRE, including any CERP engine testing not requiring

B-52 aircraft or hardware, as required to modify the Commercial-Off-The-Shelf

(COTS) engine to deliver a CERP Engine configuration conforming with the requirements in the B-52H EPS and the Propulsion System ICD consistent with the

Purpose of this program (SOW paragraph 1.2) and with the airworthiness approach as described in SOW paragraphs 4.4.14 - 4.4.16.

The NRE scope shall also include engineering work required to rectify or mitigate any non-compliance(s) to the EPS of the CERP Engine encountered during the course of

CERP integration and test activities. The CERP integration and test activities will be performed under a separate contract. SOW Attachment D, Non-Recurring

Engineering Exclusion List, is provided to clarify NRE task separation between this contract and the separate CERP integration contract(s). NOTE: The NRE Tasks included in Attachment D are provided for clarification and do not represent an all-inclusive list of NRE tasks required to deliver the CERP Engine.

NRE payments will be made at the completion of each sub-contract line item number.

The Contractor shall deliver CERP Engines (Instrumented Rapid Prototype) suitable for installation onto B-52H aircraft IAW the Engine Master Measurement

List (EMML), and the Propulsion System ICD. See SOW Attachment AF, Draft

EMML. The finalized EMML will be developed on a separate integration contract between the Contractor, integrator, and the Government.

The Contractor shall complete an EPS SRR with the Government within 60 calendar days after award of NRE to SRR is placed to ensure mutual understanding and interpretation of the EPS, relevant design, program, and technical management processes, and the initial Engine design configuration. The Contractor shall conduct the SRR IAW SOW Attachment AC, Technical Review Entrance and Exit

Criteria. (CDRL A003, DI-ADMN-81249B, Conference Agenda; CDRL A004;

and CDRL A127, DI-ADMN-81373, Presentation Material)

The Contractor shall schedule and conduct PDR(s) of the proposed modification(s) required to deliver CERP Engines (Rapid Prototype) with the Government at the component, subsystem, and system level consistent with the Contractor’s fabrication schedule for hardware release for parts that are modified from the

COTS configuration. These reviews will include instrumentation and test-enabling modifications. The Contractor shall schedule and conduct a final comprehensive

PDR, chaired by the Government, during which compatibility with the EPS will be presented. The Contractor shall conduct the PDR IAW SOW Attachment AC.

(CDRLs A003, A004, and A127)

The Contractor shall schedule and conduct detailed design review of the proposed modification(s) required to deliver CERP Engines (Rapid Prototype) with the

Government at the component, subsystem, and system level consistent with the contractor’s fabrication schedule for hardware release. These reviews will include instrumentation and test-enabling modifications. The Contractor shall schedule and conduct a final comprehensive CDR, chaired by the Government, during which compatibility with the EPS will be presented. The Contractor shall conduct the

CDR IAW SOW Attachment AC. (CDRLs A003, A004, and A127)

The Contractor shall conduct test-planning activities culminating in a TRR no later than 60 calendar days prior to test execution of each activity identified in SOW paragraph 4.4.10.1 and may utilize existing Contractor processes provided it supports the Test Review schedule requirement. The Contractor shall conduct

TRR IAW SOW Attachment AC. (CDRLs A003, A004, and A127)

The Contractor shall provide on-site personnel to render engineering and technical assistance, maintenance assistance, and guidance to support integration, ground, and flight testing of the CERP Prototype Engine. The Contractor shall ensure the personnel possess relevant experience in area(s) of assignment. The Contractor shall supply two (2) technical personnel (at least one of which shall be an

Engineer), with capability to provide up to six (6) on-site technical personnel if needed to support test objectives.

3.1.1.2 CERP Engine (Production Engine)

The Contractor shall deliver the first order of CERP Engines (Production Engine) within

12 months of delivery order issuance. All subsequent CERP Engine (Production Engine) delivery orders will be within 18 months of the delivery order issuance. The CERP

Engine (Production Engine) configuration consists of the initial baseline configuration plus any configuration changes incorporated after initial CERP Engine (Rapid Prototype) delivery.

The Contractor shall perform acceptance testing to verify that takeoff and cruise thrust

(sea level static only), engine operability (stall margin and engine response, sea level static only), engine weight and center of gravity, lubrication and fuel system functionality, customer energy extraction (horsepower and bleed), and vibration levels meet EPS and Propulsion System ICD specifications prior to delivery of a Production

Engine. All acceptance test records shall be provided to DCMA prior to DD Form 250 signature and engine acceptance.

The Contractor shall perform NRE to develop changes to the CERP Engine

(Production Engine) design and configuration when directed by Government to be performed on a To-Be-Negotiated (TBN) basis. This NRE, should it occur, would take place after acceptance, installation, and verification of the CERP Engine (Rapid

Prototype) against the requirements in the EPS.

3.1.1.3 Commercial Spare Parts Price List (CSPPL)

The Contractor shall annually provide a CSPPL comprised of the Commercial Price List appended to include all CERP unique parts. The Original Equipment Manufacturer

(OEM) material handling rate shall be applied to the CSPPL price to determine a fixed price amount for the materials.

The Contractor shall deliver components, consumables, and Line Replaceable Unit

(LRU) spares on a TBN basis based on the CSPPL price and OEM material handling rate.

3.1.2 Shipping

The Contractor shall ship engines according to existing OEM shipping instructions and commercial best practices.

3.1.2.1 Special Packaging Instructions (SPI)

The Contractor shall deliver SPI for bare engine shipping/storage and field removable item shipping/storage. SPI content and format shall be IAW Appendix E of Military

Standard (MIL-STD) MIL-STD-2073-1E (Standard Practice for Military Packaging).

(CDRL A104, DI-PACK-80121C, Special Packaging Instructions)

3.1.2.2 Significant Historical Data

Each engine shall be delivered with an Air Force Technical Order (AFTO) Form 95 as defined in Technical Order (TO) 00-20-1 (Aerospace Equipment Maintenance

Inspection, Documentation, Policies, and Procedures) documenting significant historical data. Data to be recorded shall include Mission Design Series (MDS), Type Model Series

(TMS), Part Number (PN), manufacturer, serial number, Life Limited Parts (LLP) and corresponding serial number, and complied service actions. (CDRL A020, DI-MGMT-

81564A, Significant Maintenance Historical Documentation)

3.1.3 Lifecycle Analysis

The CERP Engine design shall minimize ownership costs associated with operation, maintenance, and sustainment throughout the lifecycle of the engine.

3.1.4 Integration

The CERP Engine shall be successfully installed on the B-52H and meet all design requirements IAW the EPS and the Propulsion System ICD. The Contractor shall minimize impacts associated with cost, schedule, and performance of the B-52H CERP aircraft modification program.

4 Program Management

4.1 Contractor Program Manager (CPM)

The Contractor shall designate a CPM to be the focal point for all Contractor activities and interface with the Government. The CPM shall be responsible for administering the contract schedule, performance, maintaining workable interfaces with subcontractors and associated

Contractors. The Contractor shall identify risks, opportunities, and develop risk/opportunity response strategies. The Contractor shall provide management, technical, and logistics support to execute, sustain, and improve the overall life cycle of the engine.

4.1.1 Program Management Plan

The Contractor shall deliver a Program Management Plan. (CDRL A097, DI-MGMT-

81797, Program Management Plan)

4.1.2 Risk Management Plan

The Contractor shall develop a Risk Management Plan to encompass all parts, components/subcomponents, production, and testing. (CDRL A060, DI-MGMT-81808, Contractor’s Risk Management Plan)

4.1.3 Risk/Issue/Opportunity (RIO) Management Plan (RIOMP)

The Contractor shall perform RIO management IAW SOW Attachment B, B-52H CERP

Risk/Issue/Opportunity Management Plan. The Contractor shall participate in monthly joint

RIO Board meetings as described in the B-52H CERP RIOMP until delivery of CERP

Production engines or until closure of known risks, whichever is later. The Contractor shall ensure risk management processes cover programmatic, cost, schedule and technical RIOs.

4.1.4 Risk Management Status Report

The Contractor shall identify, track, and report RIOs and develop appropriate mitigation and handling plans. (CDRL A061, DI-MGMT-81809, CERP Risk Management Status Report)

4.2 Contractor Team Description

The Contractor shall provide within 30 calendar days of contract award an organizational chart delineating the CPM, core team members, and focal points for the areas identified below. The organizational chart shall include name, position, and commercial phone number delivered via contract letter.

a. Program Management

b. Contract Management

c. Engineering

d. Configuration Management

e. Logistics

f. Technical Support

g. Quality

4.3 Contract Management

4.3.1 Monthly Status Report (MSR)

The Contractor shall provide the Government a MSR. The Government and Contractor will work together on the requirements of the monthly status report to determine the best data to be captured as the contract matures. The Contractor shall include schedule and performance, Field Service Representative (FSR) status report per location, engine and LRU repair status and Estimated Completion Dates (ECDs), and travel trip reports IAW SOW Attachment Z, Trip Report Template. (CDRL A001, DI-MGMT-80227, Monthly Status Report)

4.3.2 Program Reviews

4.3.2.1 Program Management Reviews (PMRs)

The Contractor shall host two PMRs per year alternating between the Contractor location and a location near Tinker Air Force Base, OK (TAFB), and Contractor travel for this event shall be included as part of PMR price. The Contractor shall support topics of interest requested by the Government. The Contractor shall provide agendas and minutes for PMRs and shall track all action items to closure. (CDRLs A002, DI-ADMN-81373, Program Management Review; A003, A004, and A127)

4.3.2.2 User’s Conference/Maintenance Planning Working Group (MPWG)

The Contractor shall attend and support two User’s Conference/MPWG meetings per year IAW Air Force Manual (AFMAN) 20-116 (Propulsion Life Cycle Management for

Aerial Vehicle). These meetings will begin two years after the first B-52H aircraft installed with CERP Engines are operational. The meetings will alternate between the

Contractor location and a location near TAFB. The Contractor travel for this event shall be included as part of the User’s Conference/MPWG price. If an additional MPWG is needed, the meeting will be held via telecom. (A127)

4.3.3 Associated Contractor Agreement (ACA)

The Contractor shall establish an ACA with the aircraft integrator that allows the Contractor to obtain the approved data and technical support necessary to develop, integrate, and support the CERP Engine for the B-52H. The ACA shall be in effect at the start of this contract to ensure engine production and integration/test requirements are not impacted as a result of the inability to obtain data or support from the aircraft integrator.

4.3.4 Leading Health Indicators (LHI)

The Contractor shall provide input to the program quarterly LHI assessment by answering the questions IAW SOW Attachment P, Leading Health Indicators Checklist Questionnaire.

The Contractor’s responses will be used to identify potential risks to target War Readiness

Engines (WRE). Once risks are identified by the Government, the Contractor will coordinate with the Government per SOW paragraph 4.4.2 to develop mitigation strategies to prevent/minimize impact to WRE. (CDRL A117, DI-MISC-80508B, Technical Report-

Study/Services – LHI Checklist Questionnaire)

4.4 Engineering

4.4.1 Engineering Drawings/Models

The Contractor shall deliver any drawings and any geometric, functional, or analytical models developed during the course of engineering activities performed under this contract.

(CDRL A107, DI-SESS-81000F, Product Engineering Design Data and Associated Lists)

4.4.2 Sustaining Engineering Support

The Contractor shall support preliminary fact-finding investigations as requested by the

Government. This support shall include technical consultation with appropriate engineering groups for the review of field reports, engine records, preliminary flight data, and clarification of technical data for the duration of this contract. These services are limited to current, day-to-day operational issues or maintenance documentation and exclude engineering studies and airframe-related upgrade activities.

4.4.2.1 Technical Assistance Request (TAR)/Maintenance Assistance Request

(MAR)

The Contractor shall provide engineering support to respond to field TARs and MARs

IAW TO 00-25-107 (Maintenance Assistance), as well as other similar requests from the field when requested by the Government. The Contractor shall acknowledge receipt of

TARs and MARs and promptly respond to all requests for assistance as defined in the paragraphs below. The request is considered closed upon approval from the Government.

The Contractor shall provide the Government with the proposed solution to the request within 2 calendar days and provide a final disposition within 4 calendar days after receiving an immediate request.

The Contractor shall provide the Government with the proposed solution to the request within 10 calendar days and provide a final disposition within 13 calendar days after receiving an urgent request.

The Contractor shall provide the Government with a final disposition to the request within 40 calendar days after receiving a routine request.

4.4.3 Propulsion System Integrity Program (PSIP) Master Plan

The Contractor shall develop and implement a tailored PSIP Master Plan IAW the latest version of MIL-STD-3024 (Propulsion System Integrity Program) and SOW Attachment Q, Guidance for Propulsion System Integrity Program Master Plan. The Contractor shall provide support for Government to execute PSIP reviews IAW MIL-STD-3024 guidance.

The Contractor shall support PSIP Working Group meetings on a quarterly basis through the start of Production Engine deliveries. (CDRL A006, DI-MISC-80508B, PSIP Master

Plan)

4.4.4 Engine Trending and Diagnostics (ET&D)

The Contractor shall provide ET&D for the CERP Engines. ET&D is a multi-disciplinary approach of how to record, transfer, process, and analyze engine performance data to create actionable information. The goal of ET&D is to ascertain the health of an engine, maximize troubleshooting capability, and determine/schedule maintenance by continuously monitoring system operations, identifying abnormal conditions and associated faults, evaluating the significance, and providing response recommendations to include maintenance on the basis of evidence of need.

The Government will provide the Contractor access to CERP engine data approved for release. The Contractor shall identify adverse performance/failure trends and fault indications for the CERP Engine and its LRUs. The Contractor shall identify and report performance/failure trends and fault indications for the commercially operated variant engines and LRU components. The Contractor shall clearly identify the engine or LRU experiencing the issue by part number and serial number (if applicable). Commercial events shall be identified separately and shall be clearly identified as coming from the commercial fleet. The Contractor shall process and interpret engine health and usage trend data, analyze existing data, and identify additional data needed for long-term monitoring/trending.

(CDRL A010, DI-MISC-80508B, ET&D)

4.4.5 Engineering Studies

The Contractor shall conduct sustaining engineering studies as directed by the Government on a TBN basis. The studies will be in support of operation and sustainment and shall not be associated with the NRE to design the modified CERP Engine. The Contractor shall provide a summary of tasks performed and products developed at the conclusion of all formal analyses. All engineering studies shall include the following: background information, description, exhibit or data description, methodology, assumptions, test results, findings and conclusions, and recommendations as a result of the study to mitigate performance, reliability, or logistical issues that may have been identified as a result of the study. (CDRL

A048, DI-MISC-80508B, Engineering Studies)

4.4.5.1 Verification and Validation Plan/Report

The Contractor shall develop a Verification and Validation Plan/Report. The Contractor shall include sufficient description and documentation to allow the Government to effectively use any data and model(s) delivered with engineering studies and to confirm/validate analytical results. (CDRL A108, DI-MSSM-81751, CERP Engine

Department of Defense (DOD) Modeling and Simulation (M&S) Verification and

Validation (V&V) Plan) (CDRL A109, DI-MSSM-81752, CERP Engine Department of

Defense (DOD) Modeling and Simulation (M&S) Verification and Validation (V&V)

Report)

4.4.6 Lead-the-Fleet/Analytical Condition Inspection (LtF/ACI)

The Contractor shall work with the Government to maintain and support an LtF/ACI

Program as directed by the Government. The purpose of the Government’s LtF/ACI programs, as documented in AFMAN 20-116, is to identify potential premature component failures; identify hardware life impacts on system support costs and schedule; detect any unique durability problems; enable early analysis of trends, failure modes, and failure rates;

and assist in defining corrective actions with extra focus on any military unique hardware to ensure impacts of operational distress are fully understood.

4.4.6.1 Analytical Condition Inspection (ACI) Plan

The Contractor shall develop an ACI teardown plan which includes methodology to select engines, recommended engine/component, level of teardown recommended, specific components, analyses to be conducted on components, identified data and history to be used for analysis, and proposed price to conduct the ACI. (CDRL A110, DI-MISC-80508B, Analytical Condition Inspection Teardown Plan)

4.4.6.2 ACI

The Contractor shall support a depot-level ACI when directed by the Government on a

TBN basis. The support could include providing the teardown facility, performing the teardown, or attending teardown actions at a Government designated depot to include dirty and clean layout activities as well as further investigation determined necessary during the layout.

4.4.6.3 ACI Report

The Contractor shall deliver a report of all findings and analyses following completion of the ACI. (CDRL A111, DI-MISC-81391A, Analytical Condition Inspection Report)

4.4.7 Accelerated Mission Test (AMT)

4.4.7.1 AMT Plan

When directed by the Government, the Contractor shall develop and deliver an AMT

Plan using a system engineering approach providing goals, objectives, and measurable exit and success criteria. The AMT Plan shall trend both life-limited and non-LLP and demonstrate the life characteristics during mission testing for the overall engine. The plan shall also consider actual field monitoring and inspection systems. The Contractor shall analyze the mission profile to construct a plan to determine if the design meets the structural criteria for the engine program. See SOW Attachment J, Accelerated Mission

Test Engine Plan, for additional CDRL requirements. (CDRL A112, DI-NDTI-80566A, Accelerated Mission Test (AMT) Plan)

4.4.7.2 AMT

The Contractor shall perform the AMT testing as directed by the Government on a TBN basis. Testing would be IAW with the Government approved AMT Plan.

4.4.7.3 AMT Report

The Contractor shall analyze the results of the AMT and deliver all findings and recommendations on how best to achieve the engine’s structural design to maintain the life and durability required for the CERP Engine’s mission. See SOW Attachment K, Accelerated Mission Test Engine Report, for additional CDRL requirements. (CDRL

A113, DI- MISC-80508B, Accelerated Mission Test (AMT) Report)

4.4.8 Engine Cycle Deck and User’s Guide

The Contractor shall deliver an engine cycle deck and user’s guide for the engine in its as-proposed state and for future configuration updates. The cycle deck shall be delivered with both steady state and transient models. (CDRL A056, DI-MSSM-81966A, Gas Turbine

Engine Steady State and Transient Performance Presentation for Computer Programs)

4.4.9 Verification Matrix

The Contractor shall complete and deliver a proposed Verification Matrix and Plan that meets the requirements of Appendix C of the EPS showing how they intend to provide verification of the requirements specified in the EPS. It is not the Government’s intent to drive turbomachinery hardware redesign in order to comply with the EPS. (CDRL A066, DI-MISC-80508B, Verification Matrix Development)

4.4.9.1 Verification Matrix Report

The Contractor shall deliver a verification matrix report with substantiating reports on the analysis/test that verifies completion of EPS requirements. The Report shall meet the requirements of Appendix C of the EPS. Initial delivery shall contain already existing substantiating data. (CDRL A098, DI-MISC-80508B, Verification Matrix Report)

4.4.10 Test Plan

The Contractor shall deliver individual Test Plans for each major test activity depicted in the Engine Development Plan (paragraph 4.4.10.1). The Test Plans shall be written and conducted to applicable industry or government standards as required to achieve airworthiness. The Test Plans shall include specific test objectives, associated instrumentation/data recording requirements, and success criteria. Success criteria shall include, but not be limited to, definition of both the recorded test data and post-test analysis required to substantiate each test objective. The Government shall have the option to participate in or witness all testing; however, the Government will not delay testing due to non-availability. (CDRL A072, DI-NDTI-80566A, Engine and Subsystem Test Plans)

4.4.10.1 Engine Development Plan Presentation

The Contractor shall prepare and maintain an overarching engine development plan presentation depicting the planned major rig tests, engine tests, and integration tests to be accomplished during the program for all parts, subsystems, or systems to achieve the

Certification Baseline configuration. (CDRL A127)

4.4.11 Test/Inspection Reports

The Contractor shall deliver test and inspection reports for the tests required to achieve the

Certification Baseline configuration. (CDRL A073, DI-NDTI-80809B, Test/Inspection

Report)

4.4.12 Software Design Description (SDD)

The Contractor shall deliver a software design report for all software associated with engine performance and required for communication with other aircraft systems. The report shall contain overarching architecture and software module functionality, cybersecurity functionality (features, functions, mechanisms, services, and configurations), and input/output descriptions. Any logic diagrams or algorithms shall be flowchart based and shall enable efficient understanding of designs via software variable traceability and search

(interactive use). (CDRL A083, DI-IPSC-81435A, Software Design Description (SDD))

4.4.13 Software Version Description (SVD)

The Contractor shall deliver updated SVDs for all software modifications. (CDRL A087, DI-IPSC-81442A, Software Version Description (SVD))

4.4.14 Airworthiness Certification

The Contractor shall support the Government in obtaining a P-MTC of the CERP Engine

IAW United States Air Force (USAF) Airworthiness Bulletin (AWB) AWB-330A, Propulsion System Type Certification.

4.4.14.1 Airworthiness Certification Requirements for Multi-Core Processors

Guidance regarding additional certification implications associated with the use of multi-core processors is provided in SOW Attachment AD, Guidance for Multi-Core Processor

Use.

4.4.14.2 Airworthiness Certification Plan

The Contractor shall develop, implement, maintain, and deliver an Airworthiness

Certification Plan that documents its airworthiness program, processes and procedures, organization, interfaces, and Government certification tasks, products, and schedule. The

Airworthiness Certification Plan shall…