Att 1 PWS TH-57 Engine Repair _Final.pdf

ATTACHMENT 1 N00421-20-FOSR-M250-C20J Engine Repair PWS

PMA-273 Naval Undergraduate Flight Training Systems Rotary IPT

Performance Work Statement (PWS)

For

Rolls-Royce M250-C20J Engine Repair

03 May 2022

Distribution Statement C – Distribution authorized to U.S. Government Agencies and their contractors;

administrative/operational use, 05/03/2022. Other requests for this document shall be referred to Naval Air Systems Command Headquarters, PMA-273, Patuxent River, MD 20670.

Table of Content

1 INTRODUCTION

2 SCOPE AND OBJECTIVE

3 APPLICABLE DOCUMENTS

4 GENERAL REQUIREMENTS (ALL CLINS)

4.1 Non-Personal Services

4.2 Material, Equipment, and Facilities

4.3 Antiterrorism, Common Access Card, and Operational Security (OPSEC)

Requirements

4.3.1 Antiterrorism (AT) Level I Training

4.3.2 Contractors Requiring Common Access Card (CAC)

4.3.3 Reserved ......................................................................... Error! Bookmark not defined.

4.4 Program Management (PM) and Reporting

4.4.1 Engine Reporting

4.5 Meetings and Communication

4.5.1 Post Award Conference (PAC)

4.5.2 Recurring Meetings

4.5.3 Contract Funds Status Report (CLINs 0X01)

4.6 Reserved

4.7 Cybersecurity

4.7.1 Cybersecurity Plan

5 PERFORMANCE AND TECHNICAL REQUIREMENTS

5.1 Technical Requirements

5.1.1 TH-57 M250-C20J Engine Repair and Support

5.2 Qualifications/Certifications (ALL CLINS)

5.3 Quality Control Program (ALL CLINS)

5.3.1 Quality Assurance (QA)

5.4 Maintenance Publications, Technical Data, and Flight Manuals

6 SPECIAL REQUIREMENTS (ALL CLINS)

6.1 Safety

ACRONYM LIST

1 INTRODUCTION

The Department of the Navy Program Executive Officer for Tactical Aircraft Programs, PMA-273 Naval Undergraduate Flight Training Systems requires Depot-level (D-Level) repair and engineering investigations of Government owned M250-C20J engines manufactured by Rolls Royce Corporation, to provide Chief of Naval Air Training (CNATRA) with available aircraft necessary to achieve targeted pilot production training rates.

2 SCOPE AND OBJECTIVE

The purpose of this non-personal services task order is to provide D-Level repair of TH-57 Sea Ranger M250-C20J engines. The Contractor shall provide all labor, engineering, configuration management, facilities, tools, material, technical data, test cell, and equipment for repair of engines. Additionally, the Contractor shall effectively manage the supply chain management posture for repair part inventories; and sub-vendor contracts for M250-C20J engines. The Contractor shall forecast for all material requirements that result in all engines being returned to ready-for-issue (RFI) status. The contract shall provide support to conduct Engineering Investigations.

3 APPLICABLE DOCUMENTS

The Contractor shall perform all work in accordance with (IAW) the following applicable documents. Specific requirements are identified in the applicable PWS sections. If a date is not indicated below, the Contractor shall perform work IAW the most current version as of the date of contract award. In the event of conflict between the PWS and the references cited herein, the PWS will take precedence.

TH-57 Sea Ranger Engine Repair Applicable Documents

Document Number and Title Date

Department of Defense Manual (DoDM) 5200.01 Volume 1 Department of Defense (DoD) Information Security Program: Overview, Classification, And Declassification

28-Jul-20

DoDM 5200.01 Volume 2 DoD Information Security Program: Marking Of Classified Information

28-Jul-20

DoDM 5200.01 Volume 3 DoD Information Security Program: Protection Of Classified Information

28-Jul-20

DoDI 5200.48 Controlled Unclassified Information (CUI) 6-Mar-20

National Security Decision Directive 298 22-Jan-88

Commander, Naval Air Forces Instruction (COMNAVAIRFORINST) 4790.2D, The Naval Aviation Maintenance Program

1-Feb-21

NAVAIRINST 13700.15G, Decision Knowledge Programming for Logistics Analysis and Technical

10-Feb-20

Department of Defense Manual 5220.22-M, National Industrial Security Program Operating Manual

18-May-16

Department of Defense Directive (DoDD) 5205.02, DoD Operations Security (OPSEC) Program

29-Oct-20

Document Number and Title Date

DoD 5205.02-M, DoD OPSEC Program Manual 26-Apr-18

Office of the Chief of Naval Operations Instruction (OPNAVINST) 3432.1A, DON Operations Security

4-Aug-11

Secretary of the Navy Instruction (SECNAV) 3070.2, Operations Security 10-May-16

Airworthiness Directive 14 CFR Part 39 Latest revision

Maintenance, Preventative Maintenance, Rebuilding and Alteration 14 CFR Part 43 Latest revision

Repair Stations FAA Title 14 CFR Part 145 Latest revision

Rolls-Royce M250-C20 Series Operation and Maintenance Manual M250-C20 RR 10W2

Latest revision

Rolls-Royce M250-C20 Series Overhaul Manual M250-C20 RR 10W3 Latest revision

Rolls-Royce M250-C20 Series Illustrated Parts Catalog M250-C20 RR 10W4 Latest revision A1-H57BC-MSM-000 (Work Package 076 00, para 76-7 Enhanced Fuel Control Schedule

Latest revision in

NATEC

CNATRAFSTMEMO-07-22 Packaging of preserved engines for shipment and storage

07-Mar-22

MIL-D-3464E Desiccants, Activated, Bagged, Packaging use and Static Dehumidification.

21-Apr-87

4 GENERAL REQUIREMENTS (ALL CLINS)

4.1 Non-Personal Services

The Contractor personnel rendering the services are not subject, either by this Order’s terms or by the manner of its administration, to the supervision and control usually prevailing in relationships between the Government and its employees. The Contractor shall manage its employees and guard against any actions that relate to the performance or give the perception of personal services (see FAR Part 37).

The Contractor alone shall approve and administer leave and holidays for its employees. The Contractor shall be responsible for tasking its employees IAW the work required. The Contractor shall perform all supervision, evaluation, and disciplinary functions for its employees. If the Contractor believes that an action constitutes or creates a perception of personal services, the Contractor shall notify the Contracting Officer’s Representative (COR) immediately.

4.2 Material, Equipment, and Facilities

The Contractor shall perform all work at a Rolls-Royce Corporation Authorized Maintenance Repair and Overhaul Center (AMROC) facility using appropriate materials and equipment IAW the Rolls Royce M250-C20 repair and overhaul manuals. The Contractor shall comply with security, environmental requirements at the federal, state, local levels, and other requirements specified in this Order.

4.3 Antiterrorism, Common Access Card, and Operational Security (OPSEC) Requirements

4.3.1 Antiterrorism (AT) Level I Training

All Contractor employees, to include subcontractor employees, requiring access to Government installations, facilities, and controlled access areas shall complete AT Level I awareness training available at website https://jko.jten.mil. All Contractor employees, to include subcontractor employees, not authorized to obtain access to Department of Defense (DoD) networks (i.e. Foreign Nationals).

4.3.2 Contractors Requiring Common Access Card (CAC)

All Contractor personnel shall be eligible to perform Non-Critical Sensitive work as defined by SECNAV M-5510.30. The Contractor shall assign personnel to acquire a CAC to access the Government Information Technology (IT) systems and shall maintain the ability to access Government facilities at the request of the COR. The Contractor personnel nominated to acquire a CAC shall have a favorably adjudicated Tier-3 investigation from the Office of Personnel Management (OPM). The Contractor shall submit requests for personnel security investigation to the Government through the COR. The Government Security Office will initiate the Contractor’s Electronic Questionnaire for Investigations Processing (eQIP) and will perform a preliminary screening of the Contractor's eQIP for suitability and derogatory information. The Contractor employees shall provide all requested information pursuant to the Privacy Act of 1974. The Government Security Office may deny any Contractor employee access to Government facilities and information and may prohibit any Contractor employee from performing sensitive duties for failure to provide requested information or when derogatory or adverse information is present on the Contractor's eQIP. In such cases, the Contractor employee may not perform on this contract.

4.4 Program Management (PM) and Reporting

The Contractor shall designate a single program management Point of Contact (POC). This POC shall develop management plans to ensure that all elements of this effort are successfully executed within the program budgets and schedules to include acquisition and subcontract management and to ensure successful accomplishment of this effort.

4.4.1 Engine Reporting

The Contractor shall utilize Decision Knowledge Programming for Logistics Analysis and Technical Evaluation (DECKPLATE) Engine Transaction Report (DECKETR) for reporting status of engines within their possession for repair in accordance with attachment 4, NAVAIRINST 13700.15G DECKETR. https://deckplate.navair.navy.mil

4.5 Meetings and Communication

4.5.1 Post Award Conference (PAC)

The Contractor shall conduct a PAC at the Contractor’s facility, on or before thirty (30) calendar days after task order award. This meeting shall establish Contractor-Government lines of communication, set program objectives, manage priorities, and address any other contractual issues or concerns. The Contractor shall prepare and deliver PAC conference minutes IAW CDRL A001.

4.5.2 Recurring Meetings

The Contractor shall participate in bi-weekly Integrated Product Team (IPT) teleconference calls with CNATRA, PMA-273, and the TH-57 CLS provider to discuss the status of engine requirements and repairs.

4.5.3 Contract Funds Status Report (CLINs 0X01)

The Contractor shall prepare and deliver Contractor Funds Status Report (CFSR) IAW Contract Data Requirements List (CDRL) B001. Prime Contractors are responsible for flowing down CFSR requirements contained in their prime contracts to all subcontractors who meet the reporting thresholds. This central repository instruction applies to each separate CFSR requirement included in the contract. Contractor reports shall be prepared in accordance with any applicable contract clauses.

4.6 Reserved

4.7 Cybersecurity

4.7.1 Cybersecurity Plan

For Cybersecurity (CS) requirements see the Cybersecurity Plan (CSP), Attachment 2. Specific mentioned policies in the CS Plan can be accessed via the Cybersecurity Policy Chart at the following link: https://dodiac.dtic.mil/dod-cybersecurity-policy-chart/

The Contractor shall be required to deliver a Program Cybersecurity Implementation Plan (CSIP) or Annex CSIP to address each of the sections of the CSP. The Contractor shall demonstrate its understanding of the CSP and describe how the requirement of each of the sections of the CSP will be achieved by the Contractor. Sections of the CSP that are NOT applicable are required to be addressed.

The Contractor shall describe why a particular section is not applicable. The final Program CSIP shall be in Adobe Acrobat format with a digital signature from the Contractor cognizant authority.

If no approved Program CSIP currently exists between the Contractor and the Government, then one must be created and submitted. If an approved Program CSIP already exists and sufficiently satisfies the CSP requirements for the contract, then no new CSIP delivery is required. In such cases, the Contractor in consultation with the Government shall only submit a Contract Letter to the Government stating that all CSP requirements are satisfied by the existing Program CSIP.

If CSP requirements are NOT adequately addressed by the existing Program CSIP, then an update to the Program CSIP or a supplemental CSIP document referred to as an “Annex CSIP” shall be created to satisfy the CSP requirements. These Program CSIP updates or Annex CSIPs shall be delivered on a semi-annual (twice per year) basis IAW CDRL A005.

5 PERFORMANCE AND TECHNICAL REQUIREMENTS

The Contractor shall perform product support requirements for M250-C20J engines including logistics and material support, and repair support.

5.1 Technical Requirements

5.1.1 TH-57 M250-C20J Engine Repair and Support

The Contractor shall provide repair and return services for the M250-C20J engines that are inducted based on Government direction, to include but not limited to Test, Teardown and Evaluation (TT&E), and Mandatory Commercial Engine Bulletin (CEB) compliance and installation. The Contractor shall procure all necessary support services through an AMROC to return the engines to RFI status.

All engine maintenance shall be performed IAW the Rolls-Royce overhaul manual, M250-C20 RR 10W3 (Current Issue), and applicable documents.

For planning purposes, the anticipated number of engine inductions will be:

Contract Year Estimated Quantity

Base Year 17 Option Year 1 15

The Contractor shall submit an Engine Repair Status Report IAW CDRL A003.

5.1.1.1 TH-57 M250-C20J Engine Ship, Receive & Inspect (CLIN 0X01) The Contractor shall be responsible for the shipping costs of engines in approved containers from Naval Air Station Whiting Field (NASWF), FL to the Contractor facility. Engines and shipping containers are Government Furnished Property (GFP).

The Contractor shall perform a material condition receiving inspection on both the engine and its shipping container to ensure that all components and records are inventoried and accurately baselined. The Contractor shall prepare and deliver a Shipping and Packaging Discrepancy Report for any damage or missing items IAW CDRL A002.

5.1.1.2 TH-57 M250-C20J Engine Engineering Investigation (EI) Support (CLIN 0X02) The Contractor shall support Engineering Investigations (EI) when directed by the Government.

An EI is intended to determine the root cause and corrective action of a given failure or discrepancy. All necessary teardown, testing, and reassembly will be considered, and the Government and Contractor shall agree in advance on the scope and required actions prior to commencing an EI. The Contractor shall perform the EI in accordance with the plans set forth by the Government representative prior to or during the EI.

EIs may be directed before or after the Contractor TT&E has been initiated. When an EI is requested by the Government, the Contractor shall invite and host Government representative(s) to witness 100% of outstanding TT&E actions to include, but not limited to receiving, examination, inspection, documentation, photography, and applicable testing of deficient/damaged parts for conformance to the OEM, contractor, and subcontractor drawings, specifications, and standards.

EI exhibits shall not be opened without the Government representative present. This requirement may be waived by the Government on a case-by-case basis for planning purposes of the EI. This direction will be provided in the examination plan portion of the Joint Deficiency Reporting System (JDRS) data for each individual investigation. If Government witnessing of any specific EI actions is waived, the Contractor shall adequately record and maintain documentation of the EI engine in the as-received condition. The Contractor shall provide all relevant testing and teardown evaluation reports necessary for the Government representative to complete the EI.

Relinquishing and Shipping EI Assets (CLIN 0X04, 0X05) The Contractor shall relinquish any assets necessary for follow-on laboratory testing, which may be completed at Government facilities. The Contractor shall ship any EI assets to Navy Fleet Support Team (FST) Jacksonville, FL as directed by the Government.

5.1.1.3 TH-57 M250-C20J Test, Teardown & Evaluation (TT&E) (CLIN 0X01) The Contractor shall perform M250-C20J engine testing, as required, depending on the nature of the discrepancies listed in paragraph 5.1.1.4. The Contractor shall perform required M250-C20J engine teardown and evaluation services to determine if the engine meets the required performance specification IAW Rolls-Royce M250-C20J manuals M250-C20 RR 10W2, M250-C20 RR 10W3, and M250-C20 RR 10W4. If the engine fails to achieve minimum engine performance specification IAW Rolls-Royce M250-C20J manuals M250-C20 RR 10W2, M250-C20 RR 10W3, and M250-C20 RR 10W4, the Contractor shall identify all necessary engine repairs and maintenance actions that are required to return the engine to RFI condition.

The Scope for Test, Teardown and Evaluation is as follows:

Records Review Induct Inspect Test Preserve Update Records Package for Shipment

The Contractor shall report the completion of TT&E via the Engine Transaction Reports (ETR) using the DECKETR.

If DECKETR is not available, the Contractor shall submit ETRs using the Engine Transaction Report, Appendix C.

To satisfy the Naval audit inventory and financial reporting audit control objective; assets that are financially reported within the appropriate accounting period and/or have ETRs recorded in DECKPLATE, Engine Management within five working days of the economic event.

The COR will provide the ETR and DECKETR forms to the Contractor for submission as required. The Contractor may obtain additional guidance from the Commander of Naval Air Forces Aircraft Engine Manager via the COR.

The Contractor shall prepare and deliver a teardown deficiency report IAW CDRL A004.

5.1.1.4 TH-57 Engine Repairs (CLIN X003)

Repair is defined as those activities needed to restore an engine to RFI status by correcting discrepancies such as, but not limited to, component damage beyond allowable limits, failing power assurance tests/low power, leaking oil, making smoke, over-temperature or hot start events, over-speed events, over-torque events, exceedance of allowable metal levels in engine oil, foreign object debris (FOD), and vibration.

The Contractor shall perform required depot level repair services IAW the Rolls-Royce commercial standards. Engine repairs shall consist of returning the engine to RFI status, including component replacement, fault correction, adjustment, calibration, and acceptance testing IAW Rolls-Royce Model 250-C20J manuals M250-C20 RR 10W2, M250-C20 RR 10W3, and M250- C20 RR 10W4. If, after repair, the engine fails to achieve minimum engine performance specification during verification, the engine shall be reinducted into Contractor processing IAW Rolls-Royce Model 250-C20J manuals to be brought to an RFI condition by the Contractor.

The Contractor shall request a designation of Beyond Economical Repair (BER) from the Government for any engine for which the work scope estimates for repair and overhaul exceeds 75% of engine replacement cost, which shall be determined using the most current Rolls Royce Corporation’s catalog pricing. The BER request shall include an estimate of labor and material costs needed to return the engine to an RFI condition.

The Contractor shall update logbooks for all repaired engines and components and provide them during delivery of RFI engines to the Government IAW CDRL A004, Logbooks and Records, Aircraft and Aeronautical Equipment Status Report, Aircraft Engine Logbook.

The Contractor shall report the completion of engine processing via the ETR using the DECKETR.

If DECKETR is not available, the Contractor shall submit ETRs using the Engine Transaction Report, Appendix C. The COR will provide the ETR and DECKETR forms to the Contractor for submission as required. The Contractor may obtain additional guidance from the Commander of Naval Air Forces Aircraft Engine Manager via the COR.

The Contractor shall provide an engine test cell performance summary sheet for each engine returned as RFI that was tested on the test cell IAW Federal Aviation Administration (FAA) Title 14 Code of Federal Regulations (14 CFR) Part 145.

The Contractor shall return RFI engines within a quarterly average of 120 calendar days beginning the first day that an engine is transferred to Contractor custody at NASWF, FL.

5.1.1.5 TH-57 Engine Repairs - Over and Above (O&A) (CLIN 0X04, 0X05) Over & Above repair is defined as restoring an engine to RFI status following induction for discrepancies such as, but not limited to:

Gearbox mechanical failure (cracked or broken gearing/gear teeth) Compressor mechanical failure (cracked or broken) Power turbine wheel assembly mechanical failure

Inoperative or improper operation of engine assemblies or accessories mechanical failures Drive System Sudden Stoppage Mishap Damage (i.e., hard landing) Shipping container damage

The Contractor shall provide support to complete O&A work not previously defined elsewhere in the scope of work. The Contractor may submit an O&A Work Request for efforts outside of a standard Firm-Fixed Price repair (Levels of Repair as defined in PWS Section 5.1.1.4). The Contractor shall submit to the COR an O&A Work Request within 14 calendar days from the date of O&A determination IAW Appendix B, Over & Above Work Request (OAWR).

The Contractor shall perform O&A work as approved by the COR and IAW DFARS 252.217- 7028 and Section H of this contract for engines already inducted under the applicable CLINs.

The Contractor shall procure all materials associated with engine repairs, engine assembly, and engine container repairs. After Contractor O&A work successfully results in an RFI engine, the Contractor shall submit the actual material and labor costs for the O&A work IAW CDRL A004 Teardown deficiency report.

Airworthiness Directives and Service Bulletins (CLIN 0X04, 0X05) The Contractor shall incorporate Airworthiness Directives (AD) and Service Bulletins (SB) as directed by the COR.

The Contractor shall incorporate Government Technical Directives (TD), Maintenance Engineering Directives (MED) and Local Engineering Specifications (LES). The Contractor shall obtain these documents from the FST. as directed by the COR.

TH-57 Engine Module – Time Between Overhaul (TBO) (CLIN 0X04, 0X05) For all engines inducted, the Contractor shall notify the COR for authorization to overhaul or replace engine modules that have exceeded 80% of the Time Between Overhauls (TBO) IAW CDRL A004 Teardown Deficiency Report.

5.1.1.6 TH-57 Engine Test (CLIN 0X01)

After the Contractor has completed repairs, the Contractor shall test engine IAW the Rolls Royce Corporation AMROC and the M250-C20 engine manuals.

5.1.1.7 Preserving and Shipping Repaired TH-57 Engines (CLIN 0X01) The Contractor shall package and preserve engines IAW Rolls Royce M250 engine requirements and attachment 3, CNATRAFSTMEMO-07-22, dated 7 MAR 2022. The Contractor shall ship engines back to NASWF, FL.

5.2 Qualifications/Certifications (ALL CLINS)

The Contractor shall maintain a Rolls Royce Corporation AMROC certification and a FAA Title 14 CFR Part 145 certification (or equivalent approved by the FAA), or partner with a sub-contractor that possesses Rolls Royce Corporation AMROC certification and FAA Title 14 CFR Part 145 certification (or equivalent approved by the FAA). The Contractor shall ensure that all work on Government engines is accomplished by a facility possessing up-to-date AMROC and FAA Title 14 CFR Part 145 credentials and by artisans fully qualified and documented for the level and type of work performed.

5.3 Quality Control Program (ALL CLINS)

5.3.1 Quality Assurance (QA)

The Contractor shall implement and maintain a QA program that ensures quality maintenance practices IAW FAA Title 14 CFR Part 145.

5.4 Maintenance Publications, Technical Data, and Flight Manuals See applicable documents.

6 SPECIAL REQUIREMENTS (ALL CLINS)

6.1 Safety

The Contractor shall comply with all applicable and local safety regulations and policies governing work performed on Government engines. The Contractor shall be responsible for the safety and accountability of all of its employees and take adequate steps to confirm acceptable safety practices by any subcontractors. The Contractor shall comply with a commercially available safety program, host base safety requirements, Environmental Protective Agency (EPA) instructions and Public Law 91-596, AR 385-10, or AR 750-6.

ACRONYM LIST

Table 1 Acronym List AD Airworthiness Directives AMC Authorized Maintenance Center AMROC Authorized Maintenance Repair and Overhaul Center AT Antiterrorism CAC Common Access Card CDRL Contract Data Requirements List CEB Commercial Engine Bulletin CFR Code of Federal Regulations CFSR Contractor Funds Status Report CI Critical Information CLIN Contract Line Item Number CNATRA Chief of Naval Air Training COMNAVAIRFORINST Commander, Naval Air Forces Instruction COR Contracting Officer Representative CS Cybersecurity CSIP Cybersecurity Implementation Plan CSP Cybersecurity Plan DCMA Defense Contract Management Agency DCMA INST Defense Contract Management Agency Instruction

DECKETR Decision Knowledge Engine Transaction Reporting DECKPLATE Decision Knowledge Programming for Logistics Analysis and

Technical Evaluation D-Level Depot Level DOD Department of Defense DODD Department of Defense Directive DODI Department of Defense Instruction DODM Department of Defense Manual EI Engineering Investigations EPA Environmental Protective Agency eQIP Electronic Questionnaire for Investigations Processing ETR Engine Transaction Reports FAA Federal Aviation Administration FADEC Full Authority Digital Engine Control FAR Federal Acquisition Regulation FOD Foreign Object Debris FST Fleet Support Team GFP Government Furnished Property IAW In Accordance With IPC Illustrated Parts Catalog IPT Integrated Product Team IPTL Integrated Product Team Lead LES Local Engineering Specifications MED Maintenance Engineering Directives NASWF Naval Air Station Whiting Field NAVAIR Naval Air System Command NAVAIRINST Naval Air Systems Command Instruction O&A Over and Above OAWR Over & Above Work Request OEM Original Equipment Manufacturer O-Level Organizational level OPNAV Office of the Chief of Naval Operations OPNAVINST Office of the Chief of Naval Operations Instruction OPSEC Operational Security PAC Post Award PM Program Management POC Point of Contact PWS Performance Work Statement QA Quality Assurance RFI Ready-For-Issue SB Service Bulletins SECNAV Secretary of the Navy SECNAVINST Secretary of the Navy Instruction SGTF Small Gas Turbine FADEC TAT Turnaround Time TBO Time Between Overhauls

TD Technical Directives TT&E Test, Teardown & Evaluation