Attachment (1) Engine Repair DRAFT PWS.pdf

PERFORMANCE WORK STATEMENT FOR

DEPOT-LEVEL REPAIR OF

NAVAIR

KC-130J QUICK ENGINE CHANGE ASSEMBLIES

(AE2100D3 ENGINES)

17 August 2020

Contract Number

TBD

Approved by: __________________________________________

DISTRIBUTION STATEMENT A: Approved for public release.

CHANGE SUMMARY PAGE

This change summary page is provided to maintain a record of changes to the Performance Work Statement

(PWS). Upon receipt of a change or revision, the holder of the PWS shall incorporate the change(s) and/or revision(s) into the PWS and make appropriate entries on the record of changes list below.

RECORD OF CHANGES

Revision Date Title or Brief Description Entered by

Table of Contents 1 Scope

1.1 Weapon System Description and Use

2 Support Concept

2.1 Operational Concept

2.1.1 Maintenance Concept

3 Applicable Documents

3.1 Government Documents

3.2 Kuwait Air Force Specific Documents

3.3 Other Documents

4 General Requirements

4.1 Quality

4.2 Operations Security

4.3 Project Management

4.3.1 Project and Risk Management

4.3.2 Counterfeit Parts

4.3.3 Project Manager

4.4 Hazardous Material and Waste

4.4.1 Hazard Material and Waste Management System

4.4.2 Hazard Material and Waste Exposure

4.5 Package, Handling, Shipping and Transportation

4.5.1 Shipping, Packaging, Storage, and Containers

4.5.2 Government Furnished Property Shipping

4.6 Export Control Licenses

4.7 Engine Transaction Reporting

4.8 Cyber Security (CLIN 0018)

4.8.1 Information Assurance (IA)

5 Project Requirements (CLINs 0001, 0101, 0201, 0301, 0401)

5.1 Management Plan

5.2 Meetings and Reviews

5.2.1 Post-Award Conference (PAC)

5.2.2 Weekly Teleconferences

5.2.3 Program Management Reviews/Technical Interchange Meetings

5.2.4 Monthly Meetings or Video Teleconferences

5.2.5 Agenda

5.2.6 Meeting Minutes

5.3 Government Furnished Equipment

5.4 Government Furnished Material

5.5 Access to Systems

5.6 Airworthiness and Configuration Management

5.6.1 Airworthiness Certification Authority

5.6.2 Configuration Control

5.6.3 Technical Variances and Deviations

5.7 Engineering Investigations and Technical Services (CLIN 0018)

5.7.1 Engineering Investigation, Analytical Condition Inspection, and Product Quality Deficiency Report

6 QECA Repair Requirements (CLIN 0003,0103, 0203, 0303, 0304)

6.1 General Repair Requirements

6.1.1 Repairs

6.1.2 QECA Repairs

6.1.3 Repair Materials

6.1.4 Perform Repairs

6.1.5 Work Performed Repairs

6.1.6 Repair Action Report

6.1.7 Life Limited Components

6.1.8 Storage

6.1.9 Monthly Preservation Tasks

6.1.10 Security of Government Property

6.1.11 Cannibalization

6.1.12 Condemnation

6.1.13 Disposition of Material

6.2 Induction, Disassembly, and Assembly of QECA (CLIN 0003, 0103, 0203, 0303, 0403)

6.2.1 Records Protection

6.3 QECK Repairs

6.3.1 Deviation Requests

6.3.2 Power Section Repair

6.3.3 Operational Test

6.4 Propeller Gearbox and Gearbox Mounted Accessory Drive Repair

6.4.1 Operational Test

6.4.2 Request Disposition

6.5 Service Bulletins and Technical Directives

6.6 Shipping Requirements

6.7 RADCON

6.7.1 Radiological Control (CLIN 0016)

6.7.2 Engine Reassembly

6.7.3 QECK Reassembly

6.7.4 Procurement of Parts Related to RADCON

A.0 Appendix A: KC-130J Quick Engine Change Assembly (QECA) System Description

QECA System Description

AE2100D3 Turboprop Engine Description

KC-130J Nacelle Description

B.0 Appendix B: Projected Utilization Rates

C.0 Appendix C: Metrics

C.1 Metric Introduction

C.2 Metric Definitions

C.2.1 QECA Repair Turn-Around Time

C.2.2 PGB and GMAD Turn-Around Time

C.2.3 RADCON Survey Turn-Around Time

C.2.4 Hold Time

D.0 Appendix D: Repair Processes

D.1 Receipt and Processing

D.2 QECA Repairs - Induction

D.3 Core Engine Teardowns

E.0 Appendix E: List of Acronyms

1 Scope

This Performance Work Statement (PWS) defines the effort required for the Contractor to provide depot-level repair of KC-130J Quick Engine Change Assemblies (QECA) for the Naval Air Systems Command

(NAVAIR) KC-130J aircraft utilized by the U.S. Marine Corps (USMC), U.S. Navy (USN), and

NAVAIR-managed Foreign Military Sales (FMS) cases.

1.1 Weapon System Description and Use

The KC-130J aircraft performs USMC, USN, and Kuwait Air Force (KAF) peculiar mission requirements such as in-flight refueling for fixed and rotary wing aircraft, rapid ground refueling, and other tactical capabilities. The KC-130J aircraft QECA consists of the Rolls-Royce AE2100D3 turboprop engine and the

Lockheed Martin Quick Engine Change Kit (QECK). Additional descriptions of the propulsion system are outlined in Appendix A, KC- 130J Quick Engine Change Assembly (QECA) System Description.

2 Support Concept

This PWS details the QECA depot repair requirements and engineering and technical services required to meet the operational concept, maintenance concept, and support dates as defined herein with the repair capability meeting the Government’s annual engine operating hours outlined in Appendix B, Projected

Utilization Rates. The Government manages engines as a propulsion package referred to as a “QECA”, which is comprised of the nacelle (QECK), core engine, and the necessary components attached to them in order to make the QECA a complete operational unit. As such, the Government will ship complete QECAs to the Contractor’s depot maintenance center for repair. Propeller Gearbox (PGB) and Gearbox Mounted

Accessory Drive (GMAD) will also be shipped as individual components for repair. Attachment 2

Government Furnished Property to the contract provides a list of all QECK and engines currently managed in the NAVAIR inventory and expected to be repaired by the Contractor under this PWS. As the

Government continues to procure aircraft and spare engines, this attachment will be updated to include any additions and deletions made to the inventory. This concept includes incorporation of active service bulletins and technical directives as directed by the Government.

2.1 Operational Concept

The Government operates the KC-130J at sites within the continental United States (CONUS) and outside the continental United States (OCONUS). The sites are identified in Appendix B, Projected Utilization

Rates.

2.1.1 Maintenance Concept

Government, FMS, and Government-contracted personnel maintain the propulsion system at the organizational-level (O-level) in accordance with the approved maintenance concept as described in the

NAVAIR KC-130J Organizational Maintenance Manuals, Interactive Electronic Technical Manuals

(IETM), KAF KC-130J Organizational Maintenance Manuals, NAVAIR Technical Directives (TDs), Naval Aviation Maintenance Program (NAMP), and other Government approved data. This support includes servicing, troubleshooting, scheduled and unscheduled maintenance actions, and preservation and packing of retrograde material. The Contractor is responsible for facilities, labor, parts, material, and test equipment for depot-level repair of QECAs. Additionally, the Contractor is responsible for effectively managing repair part inventories, which includes forecasting all material requirements and vendor contracts which results in all received material being returned to ready-for-issue (RFI) status.

3 Applicable Documents

These documents are for reference purposes only. Specific requirements are identified in the applicable

PWS sections.

3.1 Government Documents

Document Number Title Date

COMNAVIRINST 4790.2C COMNAIRFORINST 4790.2C, The Naval Aviation

Maintenance Program (NAMP)

15 Jan 2017

NAVAIRINST 13700.15G NAVAIRINST 13700.15G, Decision Knowledge

Programming for Logistics Analysis and Technical

Evaluation (DECKPLATE) Engine/Propulsion System

Module (E/PSM) Management

10 Feb 2020

Department of Defense (DoD)

Manual 5220.22-M

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

(NISPOM)

18 May 2016

NAVAIRINST 4130.1E NAVAIRINST 4130.1E, Naval Air Systems Command

Configuration Management Policy and Process

14 Nov 2016

MIL-HDBK-516C MIL-HDBK-516C, Airworthiness Certification Criteria 12 Dec 2014

JSSG-2007C JSSG-2007C, Joint Services Specification Guide –

Engines, Aircraft, Turbine

10 Jun 2011

SECNAVINST 4140.2 SECNAVINST 4140.2 Management of Aviation Critical

Safety Items

25 Jan 2006

NAVAIRINST 13100.15 NAVAIRINST 13100.15, Engineering Technical Review of Commercial-Derivative Aircraft Programs

30 Mar 2002

NAS411 National Aerospace Standard (NAS) 411 Hazardous

Materials Management Program

30 Sep 2013

Title 14 CFR Part 21 Title 14 CFR Part 21, Certification Procedures for

Products and Parts

Title 14 CFR Part 39 Title 14 CFR Part 39, Airworthiness Directives

Title 14 CFR Part 145 Title 14 CFR Part 145, Repair Station Requirements

(European Aviation Safety Agency (EASA) Part 145

Certified Repair Station and Transport Canada Civil

Aviation regulations in accordance with FAA AC 43-10C, United States-Canada Bilateral Aviation Safety

Agreement Maintenance Implementation Procedures are acceptable equivalents to 14 CFR Part 145)

NAVAIRINST 5215.12B NAVAIRINST 5215.12B, NAVAIR Technical Directives

System

16 Dec 2013

DoD 4160.21 DoD 4160.21, Defense Materiel Disposition Disposal

Guidance and Procedures

2 Oct 2019

DoD 4160.28 DoD 4160.28, Defense Demilitarization: Program

Administration

9 Aug 2019

DoDI 8520.02 DoDI 8520.02, Public Key Infrastructure (PKI) and

Public Key (PK) Enabling

24 May 2011

NAVAIR 01-75GAJ-6 NAVAIR 01-75GAJ-6 Periodic Maintenance

Information Manual (PMIM)

1 Dec 2019

3.2 Kuwait Air Force Specific Documents

Document Number Title Date

KAF KC-130J Organizational Maintenance Manuals

4790.2B Kuwait Aviation Maintenance Program 4790.2B

3.3 Other Documents

Document Number Title Date

AE 2100D3 Maintenance Manual (MM) (CSP 34042)

AE 2100D3 Engine Manual (EM) (CSP 31013)

AE Series Standard Practices Manual (SPM) (CSP

40000)

AE 2100D3 Service Bulletins (SB) (CSP 34043)

AE 2100D3 Operations Manual (CSP30004)

AE 2100D3 Illustrated Parts Catalog (CSP33004)

AE 2100D3 Fault Isolation Manual (CSP34063)

AE2100D3 Component Maintenance Manuals

(CSP34044)

4 General Requirements

This section establishes the requirements for the Contractor to execute this PWS. These requirements apply to all contract line item numbers (CLINs). The Contractor shall use best commercial practices unless otherwise specified. The Contractor shall meet the metrics as defined in Appendix C, Metrics.

4.1 Quality

The Contractor's project management efforts shall satisfy the requirements of this PWS. The Contractor shall provide and use a commercial quality system that demonstrates a systems approach for managing quality, safety, and compliance with all contractual requirements in accordance with Title 14 CFR Part 145

Requirements (European Aviation Safety Agency (EASA) Part 145 Certified Repair Station and Transport

Canada Civil Aviation (TCCA) regulations in accordance with FAA AC 43-10C, United States-Canada

Bilateral Aviation Safety Agreement Maintenance Implementation Procedures are acceptable equivalents to 14 CFR Part 145). The Contractor is accountable for all sub-contractors and vendors, and as such, shall be required to implement a quality system achieving control of the quality of the services and supplies.

The Government reserves the right to perform any necessary inspections, verifications, and evaluations of the Contractor’s repair facilities at any time during contract performance to ascertain the adequacy of the quality system. For safety related visits, the Government will give the Contractor no less than 5 calendar days’ notice. The Government will give the Contractor no less than 30 calendar days’ notice for all other visits.

4.2 Operations Security

The Contractor shall establish and maintain a security program with policies and procedures that comply with the requirements of the NISPOM DODM 5220.22-M.

4.3 Project Management

4.3.1 Project and Risk Management

The Contractor shall provide project management to meet the performance requirements of the PWS. The

Contractor shall establish and maintain a risk management program for the purpose of early identification and mitigation of program risks as to not negatively impact contract performance.

4.3.1.1 Supply Chain Risk Management

The Contractor shall establish a Supply Chain Risk Management (SCRM) Program. The supply chain risk management process shall be conducted per supplier’s specifications as described in the vendors Quality

Management System. The Contractor shall utilize Attachment 3 Bill of Material (BOM), spreadsheet as the baseline of information requested for the monitoring and assessment of supply chain risks focusing on electronic components, devices that communicate with the aircraft, read/write devices and any hardware that the Contractor and Government agree present a high risk. The Contractor shall participate in a collaborative Integrated Product Team (IPT) approach with the Government to manage all SCRM related activities and shall review the results of the supply chain risks assessment with the Government during program reviews.

4.3.2 Counterfeit Parts

The Contractor shall notify the Government within 24 hours regarding any counterfeit parts or SCRM incidents upon first identification/detection/notification of the counterfeit parts IAW CDRL (A0005)

4.3.3 Project Manager

The Contractor shall designate a single point of contact responsible for the overall management and performance of the contract requirements. The Contractor shall provide, in writing, the name and contact information of the designee to the Procurement Contract Officer (PCO) within ten business days of contract award. Any change of Project Manager shall be submitted to the PCO within five business days.

4.4 Hazardous Material and Waste

The Contractor shall implement hazardous material handling procedures that comply with local, state, and federal laws and regulations concerning the use of Class I Ozone Depleting Compounds and Ozone

Depleting Substances identified in NAS411-1.

4.4.1 Hazard Material and Waste Management System

The System shall be manufactured, tested, operated, maintained, repaired, and disposed of in accordance with federal, state, local, and international Environment, Safety, and Occupational Health (ESOH) laws and regulations (i.e. OPNAVINST 5090.1C, DoDD 6050.7, and DoD INST 4715.4).

4.4.2 Hazard Material and Waste Exposure

The System shall not subject operating personnel to excess limits of toxic substances as specified in the above referenced DoD/DON Occupational Safety and Health standards.

4.5 Package, Handling, Shipping and Transportation

4.5.1 Shipping, Packaging, Storage, and Containers

The Contractor shall preserve and package for transport all Government property in accordance with the

Original Equipment Manufacturer (OEM) Repair Manuals. The primary method for shipping engines and components will be as part of QECAs. Components shall be shipped to and from the Contractor in approved shipping containers. In the event engines are shipped for repair on Government engine stands, the Contractor shall ensure Government engine stands and adapters are fully accounted for and returned to the Government in RFI condition.

4.5.2 Government Furnished Property Shipping

The Contractor shall ship all Government Furnished Property (GFP) at the request of the Contracting

Officers Representative (COR).

4.6 Export Control Licenses

The Contractor shall have export licenses for all components, parts, and materials that are International

Traffic in Arms Regulation controlled no later than 30 calendar days after contract award.

4.7 Engine Transaction Reporting

The Contractor shall comply with the E/PSM reporting procedures in accordance with NAVAIRINST

13700.15G as changes in custody, status, or conditions occur, and deliver to the information to the COR.

4.8 Cyber Security (CLIN 0018)

The Contractor shall be required to deliver a Program Cybersecurity Implementation Plan (CSIP) or

Annex CSIP to address each of the sections of the Cybersecurity Plan (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 60 business days after contract award. 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. An Annex CSIP shall address unique CSP Section "G" Assessment and

Authorization requirements if a system is being delivered under the contract and unique Section "Q"

Software requirements if software is being delivered. These Program CSIP updates or Annex CSIPs shall be submitted on a semi-annual (twice per year) basis in accordance with CDRL A006.

4.8.1 Information Assurance (IA)

The Contractor shall ensure that personnel accessing information systems have the proper and current certifications to access DOD information systems for the purpose of performing IA functions. Public Key

Infrastructure (PKI) encryption is the chosen compliant Department of Defense (DoD) standard for protecting Controlled Unclassified Information (CUI) during transmission. CUI encompasses For Official

Use ONLY (FOUO) and Sensitive Information. Failure to encrypt CUI during electronic transmission is considered a security weakness and must be reported to the Information Assurance Officer (IAO) and

Program Security Manager (PSM) via the Contractor’s responsible individual. The Contractor shall require their personnel to adhere to the required PKI policies stated herein when transmitting CUI. The Contractor shall implement DoD PKI policy per DODI 8520.02. The Contractor shall obtain and utilize PKI certificates issued by approved External Certificate Authority (ECA), for the purposes of protecting all

CUI. A substitute to utilizing approved PKI ECA certificates is for the Contractor to become a member of the Federal Bridge Certification Authority in order to issue approved Contractor issued PKI certificates with trust relationships to the DoD PKI. Approved PKI will be utilized by the Contractor and their subcontractors when transmitting CUI via electronic means. A temporary written waiver for such requirements may be granted by the Government provided that the Contractor submits a waiver request in writing to the COR.

5 Project Requirements (CLINs 0001, 0101, 0201, 0301, 0401)

5.1 Management Plan

The Contractor shall create and maintain a Management Plan to provide processes for providing project management, QECA and component repair, and engineering and technical services required under this

PWS. The Contractor shall submit the Management Plan in accordance with Contract Data Requirements

Lists (CDRL A001).

5.2 Meetings and Reviews

The Contractor’s Project Manager shall attend and participate in the meetings listed below, with the appropriate Subject Matter Experts (SMEs) to support. Meetings will be scheduled by the Government with a minimum of 30 calendar days advance notice.

5.2.1 Post-Award Conference (PAC)

The Contractor shall host a post-award conference with the Government at the Contractor’s facility no later than 45 calendar days after contract award. This meeting will cover the topics as set forth in FAR

Subpart 42.5, Post-award Orientation. Additionally, the Contractor shall demonstrate its management procedures, provide progress assessments, review technical and other specialty area status, and schedule dates for near-term critical meetings and actions.

5.2.2 Weekly Teleconferences

The Contractor shall provide weekly status reports to the COR via email of all QECAs at the depot via weekly teleconference per Attachment X. Agenda shall include assessing any engineering and logistics issues, configuration concerns and any potential or realized impacts to the production schedule.

5.2.3 Program Management Reviews/Technical Interchange Meetings

The Contractor shall host semi-annual Program Management Reviews (PMRs) and Technical Interchange

Meetings (TIMs) at the Contractor’s facility, the first of which shall occur approximately six months after

PAC.

5.2.4 Monthly Meetings or Video Teleconferences

The Contractor shall host and conduct monthly meetings by telephone or video teleconference to provide status on all open actions, performance metrics status, engine status highlights, QECA Deficiency Trends, engineering and logistical emergent issues, pending configuration changes, technical and programmatic risks, their potential impacts, and mitigation approaches.

5.2.5 Agenda

The Contractor shall prepare an Agenda for the monthly meetings and PMR/TIM(s) and submit the

Agenda in accordance with CDRL A002.

5.2.6 Meeting Minutes

The Contractor shall prepare Meeting Minutes for the monthly meetings and PMR/TIM(s) and submit the

Meeting Minutes in accordance with CDRL A003.

5.3 Government Furnished Equipment

Spare core engines will be provided as Government Furnished Equipment (GFE) in accordance with

Attachment 2 to the contract. These GFE items will be utilized only when authorized by the COR. The

Contractor shall store the USMC or FMS owned spare core engines and shipping containers in a secure storage area. The Contractor shall utilize OEM methods and procedures for maintaining the engines in a preserved and ready-for-installation state and will provide status of all GFE items during monthly meetings. The monthly preservation tasks shall include:

a. Perform general container maintenance; and

b. Ensure cleanliness and legible stenciling; and

c. Ensure all fasteners are in place and properly torqued; and

d. Inspect for damage to the outer surface of the container; and

e. Examine the external shock sensors; and

f. Monitor humidity.

g. Reclaim atmosphere (as needed)

h. Maintain preservation documentation (as needed)

5.4 Government Furnished Material

The Government will provide Government Furnished Material (GFM) listed in Attachment 2 of the contract as needed. This list includes QECK parts that may not be procurable by the AMC.

5.5 Access to Systems

The contractor shall obtain access to multiple GOV/OEM IT systems in order gain access to NATEC for

Technical Directives and Interactive Electronic Technical Manuals, and Rolls Royce Engine Tracking

System and OEM manuals/service bulletins.

5.6 Airworthiness and Configuration Management

5.6.1 Airworthiness Certification Authority

NAVAIR is the airworthiness certification authority for the KC-130J aircraft. NAVAIR’s airworthiness certification for KC-130J propulsion system leverages the Federal Aviation Administration (FAA) type certification and civil airworthiness standards as a baseline in accordance with MIL-HDBK-516C, JSSG-

2007C, and NAVAIRINST 13100.15. The current manuals listed in Section 2.0 (IETMS, depot maintenance manuals, illustrated parts breakdown), approved service bulletins per Attachment 9 and formal TDs form the baseline certification for airworthiness of depot-repaired engines.

5.6.2 Configuration Control

The Contractor shall review the engine logbooks for NAVAIR TDs requiring incorporation during repair and document the compliance of the TD upon completion. Applicable NAVAIR TDs are available for download from the Naval Aviation Technical and Engineering Services Command's (NATEC) website www.natec.navy.mil. The current maintenance manuals, Illustrated Parts Breakdown (IPB), Approved

OEM Service Bulletins (Attachment X), and Formal Technical Directives form the baseline configuration of the KC-130J QECA. Applicable OEM service bulletins are available for download from the engine tracking system (ETS), can be located at https://2100.enginetracking.com. Document all incorporated

OEM service bulletins in ETS.

5.6.3 Technical Variances and Deviations

The Contractor shall provide a copy of the FAA approved technical variance (TV) via electronic means to the COR when the Contractor deviates from the authorized configuration and or use of unauthorized parts or components to all AE2100D3 engines repaired under this PWS. A TV is defined as any deviation or variance that is outside the approved configuration, tolerances, or limits defined in the OEM repair manuals. Additionally, the Contractor shall make available all relevant data, analysis, and assumptions for review by NAVAIR technical authority experts to document the nature of the change, support why the change is needed, what testing was completed to ensure safety, and if the change is permanent or temporary. Proposed configuration changes shall be provided to NAVAIR prior to incorporation for downstream logistics and interface considerations.

5.7 Engineering Investigations and Technical Services (CLIN 0018)

5.7.1 Engineering Investigation, Analytical Condition Inspection, and Product Quality Deficiency Report

The Contractor shall provide, at the request of the Government and with COR approval, support investigations of items designated special interest per the COMNAVAIRFORINST 4790.2C. These tasks are Engineering Investigations (EIs), Analytical Condition Inspections (ACI) and Product Quality

Deficiency Reports (PQDR). Government engineering personnel will coordinate with the Contractor on the induction of EI, ACI or PQDR items and provide specific disassembly, inspection, and data recording instructions. The Contractor shall research component history to include hours/cycles accrued, serviceability, repairs, and installations/removals, at a minimum. Disposition instructions and release of the EI, ACI, or PQDR item will be provided by Government engineering upon completion of the EI, ACI, and PQDR. The time required to support the EI, ACI, shall not be counted against the Contractor's TAT.

The Contractor shall compile root and corrective/preventative actions, analysis and test data and submit in accordance with CDRL B001.

http://www.natec.navy.mil/ https://2100.enginetracking.com/

6 QECA Repair Requirements (CLIN 0003,0103, 0203, 0303, 0304)

6.1 General Repair Requirements

6.1.1 Repairs

The following requirements shall apply to all repairs performed under sections 5.0 and 6.0 of this PWS.

6.1.2 QECA Repairs

The Contractor shall perform all unscheduled and scheduled repairs, maintenance actions, restoration, tests, FAA- approved airworthiness directives in accordance with Title 14 CFR Part 39, and configuration changes in accordance with the baseline configuration, established in section 5.3.2 of this PWS. Future service bulletins will be addressed in accordance with the FAR 52.212-4(c) Contract Terms and

Conditions -- Commercial Items.

6.1.3 Repair Materials

The Contractor shall ensure the safety and quality of all materials used in repairs and ensure that all new, repaired, or refurbished parts are FAA-certified (or equivalent TCCA or EASA), in accordance with Title

14 CFR Part 21 and accompanied by a copy of the work order, FAA Form 8130-3 or an equivalent

Contractor Certificate of Conformance (COC), and FAA Form 8110-3 or an equivalent Certificate of

Release, Test, and Conformity.

6.1.4 Perform Repairs

The Contractor shall provide all labor, parts, and material, excluding Attachment 2 items necessary to perform repairs.

6.1.5 Work Performed Repairs

The Contractor shall provide documentation to certify all work was accomplished in accordance with

Federal Aviation Regulation Part 145, Repair Station Operators (or equivalent TCCA or EASA), and record all maintenance, modifications, and component life information into the applicable NAVAIR/KAF logbook and engine data disks.

6.1.5.1 Certificate of Conformance

The Contractor shall ensure that all work accomplished has been certified as airworthy and properly documented per FAR 46.504.

6.1.5.2 Critical Safety Items

The Contractor shall provide notification of any issue concerning a Critical Safety Item (CSI) part listed in

Attachment 4 CSI List to the COR and FAA (or equivalent TCCA or EASA) via email within two business days.

6.1.6 Repair Action Report

The Contractor shall compile all repair data and submit a Repair Action Report on repaired QECAs, engines, modules, and components in accordance with CDRLs A004.

6.1.7 Life Limited Components

The Contractor shall replace all life limited components referenced in the KC-130J PMIM with less than

800 cycles life remaining per the recorded cycles in the Engine Logbook.

6.1.8 Storage

The Contractor shall, upon Government direction, provide indoor storage for NAVAIR or FMS-owned spare core engines and shipping containers.

6.1.9 Monthly Preservation Tasks

The Contractor shall use approved OEM methods and procedures for maintaining the engines in a preserved and RFI state.

6.1.10 Security of Government Property

The Contractor shall perform the following monthly preservation tasks:

a. Perform general container maintenance; and

b. Ensure cleanliness and legible stenciling; and

c. Ensure all fasteners are in place and properly torqued; and

d. Inspect for damage to the outer surface of the container; and

e. Examine the external shock sensors; and

f. Monitor humidity.

g. Reclaim atmosphere (as needed)

h. Update preservation documentation (as needed)

6.1.11 Cannibalization

The Contractor shall request, in writing to the COR, approval from the Government to cannibalize repairable parts, components, or modules from other QECAs. Cannibalization approval by the Government shall not constitute grounds to extend the TAT of the QECA from which the parts were cannibalized.

Cannibalization changes shall be tracked in weekly depot metrics tracker (Attachment X).

6.1.12 Condemnation

Parts, components, and modules shall be considered for condemnation if their repair exceeds the repairable limits specified in the applicable OEM manuals. The Contractor shall not repair condemned parts unless authorized in writing by the COR. All condemned parts shall be reported in the Final Condition Report /

Certificate of Conformance (CoC), and the Contractor shall request the Government provide disposition guidance for all condemned parts.

6.1.13 Disposition of Material

The Contractor shall include in its NAVAIR approved Management Plan (CDRL A001) the process for disposal of Government property and shall include the requirements stipulated in the FAR Part 45, Government Property; DoD 4160.21-M, Defense Material Disposition Manual; and DoD 4160.28, Defense

Demilitarization: Program Administration. The Contractor shall dispose of all removed Government property in accordance with the Management Plan.

6.2 Induction, Disassembly, and Assembly of QECA (CLIN 0003, 0103, 0203, 0303, 0403)

The Contractor shall notify the COR/Government via email of receipt of a QECA. The Contractor shall receive and induct all QECAs provided by the Government that have identified discrepancies requiring partial or full disassembly. The Contractor shall perform receiving, inspection, removal of core engine, minor repair of QECK, reinstallation of the core engine, final inspections, report preparations, and logbook and record card update actions to return the QECA to RFI condition as outlined in Appendix D, Repair

Processes. Flight hours are defined as the amount of hours as recorded by the Government in Naval

Aviation Flight Records (NAVFLIR).

The Contractor shall submit Engine Transaction Reports (ETR) to the COR. In the case of lost or missing maintenance records, the ETR entries shall identify what records were not received.

6.2.1 Records Protection

The Contractor shall protect all maintenance records from damage or loss IAW COMNAVAIRFORINST

4790.2C Chapter 5.

6.3 QECK Repairs

A QECK depot-level repair encompasses the structural components, all attaching components, wiring, ducts, and tubing of the QECA that are not part of the core engine. Repairs of the QECA Transport

Dollies/Stands and the QECA protective bag/cover will be included in the QECK repair effort.

6.3.1 Deviation Requests

The Contractor shall obtain Government approval, in writing via the COR, for any change to or deviation from QECK and subcomponents of the QECK prescribed repair procedure or test specification(s) in approved OEM and Government Maintenance manuals. The COR will provide disposition within five business days.

6.3.2 Power Section Repair

Core engine is defined below and are inclusive of all attaching components, wiring harnesses, tubing, and ducting. Repairs are inclusive of all disassembly, inspections, repairs, component testing, reassembly of

Power Section and Torquemeter, and operational testing of the core engine.

a. Power Section; and

b. Torquemeter; and

c. Power Unit Accessory Drive.

6.3.3 Operational Test

Upon reassembly of a core engine, the Contractor shall perform an operational test of the engine to certify as RFI. All engines repaired by the Contractor shall have a maximum measured gas temperature (MGT) value of 1366°F to produce a 100% shaft horse power (SHP) rating of 4637 SHP at Sea Level, Static, Standard Day conditions in order to be considered RFI.

6.4 Propeller Gearbox and Gearbox Mounted Accessory Drive Repair

This section applies to the AE2100D3 PGB and GMAD units that are received by the Contractor either installed in a QECA or as stand-alone units. Repair upon receipt of executed Task Order, the Contractor shall repair the PGB and GMAD.

6.4.1 Operational Test

Upon repair of the PGB and GMAD, the Contractor shall perform an operational test of the units to certify as RFI.

a. For PGB and GMAD units received installed, the operational test should be accomplished once installed on the core engine.

b. For PGB and GMAD units received as standalone assets, the test may be completed using a standalone test platform or as an installed unit on a core engine.

6.4.2 Request Disposition

Upon successful completion of the operational test of standalone assets, the Contractor shall request

COR/Government disposition from the COR for the PGB and GMAD.

6.5 Service Bulletins and Technical Directives

The Contractor shall provide a list and pricing of labor and materiel required for service bulletins and technical directives to be incorporated as directed by the Government during engine repair. Except for no-cost service bulletins incorporated as part of repairs, the Contractor shall incorporate new service bulletins and technical directives beyond the baseline established at initial contract award after receipt of formal

PCO approval.

Service bulletins to be incorporated shall be based on the below categories:

1. No Cost to Incorporate

2. Minor – Inspection requiring abnormal labor burden and/or repair using existing tooling/skillsets

3. Major – Repair using unique tooling/skillsets and/or incorporation of hardware that is outside of the normal repair scope

6.6 Shipping Requirements

The Contractor shall coordinate and ship QECAs and components as directed by the COR. Transportation costs for shipment of the QECAs and components from the Government site to the Contractor’s facility are the responsibility of the Government. The Contractor shall ship QECAs and PGBs from the Contractor’s facility to the Government designated CONUS, Japan, or KAF location via the TAC (Transportation

Account Code) or appropriate CLIN as determined by the COR. The contractor shall ensure that all engine shipping bags are RFI prior to shipment, replacing unserviceable protective bag/cover as required. The below listed destinations and supported activities are provided as standard shipping locations but are not all inclusive as other events may require shipments to alternate destinations to support fleet requirements.

CONUS: The following geographical areas are utilized to support USMC, USMCR, activities that are based or operating within the Continental US.

Destination Activity Supported

Cherry Point , NC VMGR-252

Patuxent River, MD VX-20

Newburgh, NY VMGR-452

Fort Worth, TX VMGR-234

San Diego, CA VMGR-352

Pensacola, FL Naval Flight Demonstration Squadron

Japan: The following geographical area is utilized to support USMC, USMCR, activities that are based or operating outside of the Continental US.

Destination Activity Supported

Iwakuni, Japan VMGR-152

Kuwait Air Force: QECAs and PGBs shall ship to one of the following locations of the Contractor’s choice in support of KAF activities that are based or operating outside of the Continental US.

Destination Activity Supported

Jamaica, NY Kuwait (Freight Forwarding Activity)

TBD, United Kingdom Kuwait (Freight Forwarding Activity)

Hamburg, Germany Kuwait (Freight Forwarding Activity)

6.7 RADCON

The Contractor shall perform repairs under this section in conjunction with the repairs listed in Section 5 of this PWS. The intent of this section is to provide for repairs considered beyond the scope of section 5 of this PWS. All additional repairs shall be accomplished using the same process outlined in all repair sections of the PWS. Additional repairs are:

6.7.1 Radiological Control (CLIN 0016)

(RADCON) QECA Survey Under this CLIN, the Contractor shall disassemble, survey, inspect, and decontaminate a radiation contaminated QECA in accordance with contract AE2100 RADCON Engine

Teardown Inspection Plan (Attachment 3) complying with all local laws and regulations, and the following:

a. The Contractor shall make the radiological survey facility available for Government site survey within 30 business days of contract award.

b. The Contractor shall perform up to three decontamination attempts if the component is found above the limits.

c. If there is less than a 10% reduction in radioactivity between the initial survey and the first decontamination attempt, and the component remains above limits, the item shall be quarantined. If the component remains above limits after the third decontamination attempt, the component shall be quarantined.

d. The Contractor shall retain all quarantined components at the radiological survey facility until the

Government provides disposition instructions.

e. The Contractor shall complete and submit all Survey Plan Appendices and associated documentation completely, correctly, and within the guidelines provided in the survey plan. The

Contractor shall submit the appendices for each QECA survey as each appendix is completed.

f. The Contractor shall retain all QECAs at the radiological survey facility until the component is cleared for release.

All QECAs surveyed under this CLIN will be reviewed and cleared by the Government prior to release for reassembly. This release shall be provided by the Government via Naval message. The Contractor shall perform reassembly of the QECA as appropriate.

6.7.2 Engine Reassembly

Under this CLIN, the Contractor shall inspect and reassemble an engine received in a disassembled state.

These engines were disassembled during RADCON survey and have been cleared for reassembly by

NAVSEA. The Contractor shall perform the reassembly under this CLIN concurrently with the repair procedures performed under the QECA repair CLIN (XXXX), as outlined in Section 6 of this PWS necessary to restore the engine to RFI condition.

6.7.3 QECK Reassembly

Under this CLIN, the Contractor shall inspect and reassemble a QECK received in a disassembled state.

These QECKs were disassembled during RADCON survey and have been cleared for reassembly by

NAVSEA. The Contractor shall perform the reassembly under this CLIN concurrently with the repair procedures performed under the QECA repair CLIN (XXXX), as outlined in Section 6 of this PWS necessary to restore the engine to RFI condition.

6.7.4 Procurement of Parts Related to RADCON

The Contractor shall provide a list of priced components, parts, and materiel that are quarantined during

RADCON surveys that are required for the reassembly of a QECA. Once approved by the PCO or COR, the Contractor shall provide the replacement part.

A.0 Appendix A: KC-130J Quick Engine Change Assembly (QECA) System

Description

QECA System Description

The KC-130J propulsion system is comprised of the AE2100D3 turboprop engine manufactured by Rolls-

Royce and the nacelle (commonly referred to as “QECK”) assembly manufactured by Lockheed Martin.

The QECA is maintained as a complete ready to install and operate assembly.

AE2100D3 Turboprop Engine Description

The Rolls-Royce AE2100D3 engine is comprised of five major modules:

a) Power Section

b) Torque meter

c) Power Unit Accessory Drive

d) Gearbox Mounted Accessory Drive

e) Propeller Gearbox (PGB)

Each engine includes the below listed major components and Line Replaceable Units (LRU):

1. Starter 11. Starter control valve 21. Torque meter pick-ups

2. Compressor inlet pressure sensors

12. Compressor inlet temperature sensors

22. Thermocouples

3. Full authority digital electronic control

(FADEC) (2)

13. Indicating magnetic plugs 23. Fuel pump metering unit

4. Compressor variable geometry actuator

14. Anti-ice valve 24. Permanent magnetic alternator

5. Igniters 15. Ignition exciters 25. Fuel cooled oil cooler

6. NP harness 16. NP speed sensor

26. Power Section lube and scavenge pump

7. Fuel nozzles 17. NG speed sensors 27. PGB lube and scavenge pump

8. Bleed control valve 18. All engine tubing 28. Prop shaft flange adapter

9. FADEC A harness 19. FADEC B harness 29. Compressor bleed valves

10. EMS harness 20. Fuel flow meter

KC-130J Nacelle Description

The Lockheed Martin KC-130J Nacelle is comprised of the following:

1. Nacelle structure 8. Engine and aircraft electrical system

2. Engine mounts 9. Engine fuel system

3. Electric generator 10. Engine control and indicating systems

4. Propeller pitch control unit 11. Engine oil system

5. Propeller overspeed governor 12. Engine starting system

6. Brush block and bracket 13. Engine hydraulic system

7. Engine and aircraft pneumatic system

The above lists are intended to detail only the major modules and components of the engine; they are not all- inclusive. A thorough breakdown of the engine that includes all parts, repairable as well as consumable, can be found in the Rolls-Royce AE2100D3 Illustrated Parts Catalog or the NAVAIR KC-

130J Organizational Maintenance Manuals.

B.0 Appendix B: Projected Utilization Rates Projected KC-130J AE2100D3 USMC/USN Overhauls:

Failure Mode FY2022 FY2023 FY2024 FY2025 FY2026

Performance 11 13 10 10 9

Oil Leak/Pressure Issues 18 9 16 12 10

Foreign Object Damage (FOD) 9 13 5 8 9

Vibrations 8 6 8 11 12

Miscellaneous 1 9 5 8 5

Metal in Oil 3 3 6 4 5

External Engine Damage 5 3 4 3 4

Scheduled Engine Removal

(SER)

2 3 3 2 2

Totals 57 59 57 58 56

C.0 Appendix C: Metrics

C.1 Metric Introduction

This Appendix defines the metrics selected to measure the Contractor’s performance effectiveness in meeting the requirements established in the Performance Work Statement. The Contractor shall be held responsible for meeting established metrics in accordance with clause H-1 Liquidated Damages and any other remedies available under this contract. These metrics were selected in order to institute a program that provides Government operating forces with the QECA readiness necessary to meet their worldwide national security commitments.

Throughout the contract period, Contractor performance to metrics will be continually monitored per the

Quality Assurance Surveillance Plan (QASP). Formal reviews of performance will be held at each

Program Management Review. At each semi-annual review the cause and corrective actions associated with non- performance to metrics will be discussed and addressed.

In cases of non-performance to metrics, the following causes and results will be addressed by the

NAVAIR and Contractor program management group:

Validity of metric and measurements or data feeding the metric

Impact on fleet readiness and operation due to the metric infraction or non-attainment

Reason or cause for the metric infraction; both Government-caused and Contractor-caused

Corrective action taken and results (metric performance due to timing associated with corrective action implementation)

The Metrics for performance monitoring and management are:

Metric Name Metric

QECA Repair Turn-Around Time (TAT) 100 Days

PGB and GMAD TAT (Stand

Alone) RADCON Survey

TAT

45 Days

90 Days

NOTE: In instances where QECA components are quarantined due to radiological contamination, the Contractor shall notify the Government and provide a proposal for the proposed price of the affected parts. At that time, the QECA repair TAT and the price of the affected parts will be mutually agreed upon by NAVAIR and the Contractor and a modification will be issued delineating agreement.

C.2 Metric Definitions

C.2.1 QECA Repair Turn-Around Time

The QECA Repair TAT conveys the Government’s requirements for repair responsiveness. The Contractor can use this metric to help determine the proper capacity of its repair facilities, repair part inventories, and subcontract requirements. The TAT starts once the Government issues a task order for repair of a QECA and the Contractor receives the QECA. TAT ends when the Contractor provides copies of repair documentation and notifies the COR that the QECA is RFI and ready for shipment.

Date RFI – Date task order issued and QECA received = Total Days TAT

C.2.2 PGB and GMAD Turn-Around Time

The PGB and GMAD TAT convey the Government’s requirements for repair responsiveness. The

Contractor can use this metric to help determine the proper capacity of its repair facilities, repair part inventories, and subcontract requirements. The TAT starts once the Government issues a task order for repair of a specific module and the Contractor receives the specific module. TAT ends when the

Contractor provides copies of repair documentation and notifies the COR that the module is RFI and ready for shipment.

Date RFI – (Date task order issued and PGB received) = Total Days TAT

C.2.3 RADCON Survey Turn-Around Time

The RADCON Survey TAT conveys the Government’s requirements for survey responsiveness. The

Contractor can use this metric to help determine the proper capacity of its radiological survey facility. The

TAT starts once the Government issues a task order for survey of a QECA and the Contractor receives the

QECA. TAT ends upon the Government’s review and acceptance of all the survey data for the QECA.

If multiple QECAs are received, the second QECA TAT will start once the first QECA’s survey has been reviewed and accepted. This process will continue for the remaining QECAs. Each subsequent QECA start date shall not exceed 90 days from the previous QECA’s start date. See example below.

RADCON Engine TAT Start TAT End

First QECA Order is issued and QECA is received

Upon Government’s review and acceptance of all survey data for the QECA

Subsequent QECAs Once the first QECA’s survey has been reviewed and accepted, but no later than 90 days from the previous QECA’s start date.

Upon Government’s review and acceptance of all survey data for the

QECA

C.2.4 Hold Time

The Contractor shall notify the Government, in writing via the COR, of any anticipated or actual work stoppage that affects turnaround time at the fault of the Government. Hold time in calendar days will be subtracted from the TAT for the engine under repair. The Government and the Contractor will mutually agree upon assessment of hold time.

When a QECA/PGB is at a work stoppage: TAT will not stop until the Contractor notifies the COR of a work stoppage due to lack of either a Government supplied part/component or required Government provided technical guidance. The repair TAT will re-start at the point in time that either the required

Government provided part is received at the depot or the technical guidance is received allowing repair work to continue. The number of calendar days between the Contractor notification of the work stoppage and the receipt of the Government part/technical guidance will count as Hold Time to be excluded from the TAT for that QECA/PGB repair.

When a work stoppage has not yet occurred: TAT will not stop until the Government and the Contractor mutually agree upon assessment of hold time due to lack of either a Government supplied part/component or required Government provided technical guidance. The Contractor will provide an estimate of the impact to schedule in calendar days. The Government and the Contractor will mutually agree to the TAT impact at the start of hold time and any additional hold time beyond what was initially agreed upon. The number of actual calendar days on hold will be subtracted from the final TAT for that QECA/PGB repair.

D.0 Appendix D: Repair Processes

D.1 Receipt and Processing

a. The COR will notify the Contractor of inbound QECAs and standalone components.

b. The Contractor shall notify the COR upon receipt.

c. The Contractor shall perform a receiving inspection of the QECA and its Transport

Dollies/Stand, PGB and its container and notify the COR of any shipping related damage within three business days of receipt at the Contractor’s facility. If any significant damage is identified the contactor shall provide written description and photographs via email to the COR.

d. The COR will provide authorization for induction of the QECA or standalone components.

D.2 QECA Repairs - Induction

a. The Contractor shall inspect the QECA for damage and missing components, review associated log books for completeness, and notify the COR of the “As

Received Condition” within five business days of induction. Logbooks and maintenance records shall be inspected to ensure accurate reporting of serial number information and completeness of each record in accordance with

COMNAVAIRFORINST 4790.2C. If the serial number on the maintenance record is not the same as the item received, or if records are missing or deficient, the Contractor shall notify the COR.

b. The COR will acknowledge the “As Received Condition” report and provide any special requirements for testing or disassembly related to a Deficiency

Report or Engineering Investigation within five business days.

c. The Contractor shall perform the following:

1. Remove core engine from QECA.

2. Perform detailed inspection of the QECK.

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