Attachment 1 PWS TH-57 Engine Repair (DRAFT) 03-01-22.pdf

ATTACHMENT 1 N00421-20-FOSR-TH-57 Engine Repair PWS

PMA-273 Naval Undergraduate Flight Training Systems TH-57 Sea Ranger

Performance Work Statement (PWS)

For

Rolls-Royce M250-C20J Engine Support

XX November 2021

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

administrative/operational use, 3/26/2020. 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 Government Responsibilities

4.2 Non-Personal Services

4.3 Material, Equipment, and Facilities

4.4 Antiterrorism (AT), Common Access Card (CAC), and Operational Security

(OPSEC) Requirements

4.4.1 Antiterrorism Level I Training

4.4.2 Contractors Requiring Common Access Card (CAC)

4.4.3 Contractors Not Requiring CAC and Requiring Access to a DOD Facility or Installation

4.5 Program Management (PM) and Reporting

4.5.1 Engine Reporting

4.6 Meetings and Communication

4.6.1 Post Award Conference (PAC)

4.6.2 Recurring Meetings

4.7 Transition

4.8 Cybersecurity

4.8.1 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 Contractor Agreements ....................................................... Error! Bookmark not defined.

5.3.1 Original Equipment Manufacturer (OEM) License Agreement... Error! Bookmark not defined.

5.3.2 Associate Contractor Agreement (ACA) ....................... Error! Bookmark not defined.

5.4 Quality Control Program (ALL CLINS)

5.4.1 Quality Assurance

5.4.2 Subcontract Management ............................................... Error! Bookmark not defined.

5.5 Maintenance Publications, Technical Data, and Flight Manuals

5.6 Travel .................................................................................... Error! Bookmark not defined.

6 SPECIAL REQUIREMENTS (ALL CLINS)

6.1 Safety

6.2 Security ................................................................................. Error! Bookmark not defined.

6.3 Government Furnished Property, Facilities, Information, and Services ............. Error!

Bookmark not defined.

6.4 Work Schedule ..................................................................... Error! Bookmark not defined.

6.5 Overtime, Surge, and Over and Above Work ................... Error! Bookmark not defined.

6.6 Training ................................................................................ Error! Bookmark not defined.

6.7 Physicals ................................................................................ Error! Bookmark not defined.

6.8 Data Rights ........................................................................... Error! Bookmark not defined.

6.9 Strike Plan and Labor Dispute ........................................... Error! Bookmark not defined.

6.10 Distinctive Requirements for OCONUS ............................ Error! Bookmark not defined.

6.11 Vehicle and Equipment Operation ..................................... Error! Bookmark not defined.

6.12 Reporting Requirements ..................................................... Error! Bookmark not defined.

6.13 Web-Based Information System ......................................... Error! Bookmark not defined.

7 CDRL DELIVERABLES (ALL CLINS)

8 TERMS DEFINED ............................................... ERROR! BOOKMARK NOT DEFINED.

9 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 M250 engines manufactured by Rolls- Royce Corporation, to provide Chief of Naval Air Training (CNATRA) with available aircraft necessary for pilot production.

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 and test cell and equipment for repair of engines. Additionally, the Contractor shall effectively manage the repair part inventories and vendor contracts for TH-57 Sea Ranger engines to include forecasting all material requirements that result in all received material 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 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

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 Vrevidion

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

Latest revision

Repair Stations 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

4 GENERAL REQUIREMENTS (ALL CLINS)

4.1 Government Responsibilities

The Government will maintain the engines at the organizational-level (O-level) IAW the approved maintenance concepts as described in the Naval Air Systems Command (NAVAIR) Organizational Maintenance Manuals, NAVAIR Technical Directives (TDs), Naval Aviation Maintenance Program, and other Government approved data. This includes servicing, troubleshooting, scheduled and unscheduled maintenance actions, and preservation and packing of retrograde material.

4.2 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 will be responsible for tasking its employees IAW the work required. The Contractor will 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 Task Order Contracting Officer (TOCO) immediately.

4.3 Material, Equipment, and Facilities

The Contractor shall perform all work at a Rolls-Royce Corporation Authorized Maintenance Repair and Overhaul Center (AMROC). The Contractor must comply with security, environmental requirements at the federal, state, local levels, and other requirements specified in this Order.

4.4 Antiterrorism (AT), Common Access Card (CAC), and Operational Security (OPSEC) Requirements

4.4.1 Antiterrorism Level I Training

Not applicable.

4.4.2 Contractors Requiring Common Access Card (CAC)

All Contractor personnel must be eligible to perform Non-Critical Sensitive work as defined by SECNAV M-5510.30. The Contractor shall assign personnel to acquire a Common Access Card (CAC) to access the Government IT systems and have the ability to access Government Facilities at the request of Contracting Officer’s Representative (COR). The Contractor personnel assigned to acquire a CAC are required to have a favorably adjudicated Tier-3 investigation from the Office of Personnel Management (OPM). The Contractor shall submit a request for personnel security investigation to the U.S. Government through the COR. The Government Security Office shall initiate the Contractor's Electronic Questionnaire for Investigations Processing (eQIP) and shall do a preliminary screening of the Contractor's eQIP for suitability and derogatory information. The Contractor employee shall provide all requested information pursuant to the Privacy Act of 1974.

The Government Security Office may deny the Contractor access to Government facilities and information and may prohibit the Contractor from performance of 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 the contract.

4.4.3 Contractors Not Requiring CAC and Requiring Access to a DOD Facility or Installation

Not applicable.

4.5 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.

4.5.1 Engine Reporting

The Contractor shall provide Decision Knowledge Programming for Logistics Analysis and Technical Evaluation (DECKPLATE) Engine Transaction Report (DECKETR) reporting status of engines in accordance with NAVAIRINST 13700.15G DECKETR.

https://deckplate.navair.navy.mil

4.6 Meetings and Communication

4.6.1 Post Award Conference (PAC)

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

4.6.2 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.

4.7 Transition

Not applicable.

4.8 Cybersecurity

4.8.1 Cybersecurity Plan

For Cybersecurity (CS) requirements see the Cybersecurity Plan (CSP), Attachment X. Specific mentioned policies in the CS Plan can be accessed via the Cybersecurity Policy Chart at the following link: http://iac.dtic.mil/csiac/ia_policychart.html

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. 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 IAW CDRL A005 Cybersecurity Implementation Plan.

5 PERFORMANCE AND TECHNICAL REQUIREMENTS

The Contractor shall perform product support requirements including logistics and material support, engine repair support to the TH-57 Turboshaft Engines.

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 require repair beyond the Organizational maintenance level 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 AMROC to return the engines to RFI status from the date of the Government request for engine repair.

Engine repair will be performed IAW the Original Equipment Manufacturer (OEM) overhaul manual, M250-C20 RR 10W3 (Current Issue).

For planning purposes, anticipate engine repair quantities:

Contract Year Base Option year 1 Quantities 17 11

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 is responsible for the shipping costs of engines (in containers) from NASWF, FL as directed by the Government.

The Contractor shall perform an engine and container material condition receiving inspection to ensure all components and records are inventoried and accurate. The Contractor shall prepare and deliver a Shipping and Packaging Discrepancy Report for any damage 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) as directed by the Government, before and after the TT&E has been performed. The Contractor shall host Government Personnel Representative(s) who will witness 100% of TT&E process 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. EIs are intended to determine root cause and corrective action of a given failure or discrepancy; all necessary teardown, testing, and reassembly will be considered prior to beginning investigation. All parties shall agree upon the scope of the investigation prior to commencing. The contractor shall perform the EI in accordance with the plans set forth by the government representative prior to or during the investigation.

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 investigation. In the event it this occurs, provisions shall be made to document the as-received condition of the EI asset.

The contractor shall provide all relevant testing and teardown evaluation reports necessary for the government representative to complete the EI report. The contractor shall relinquish any assets necessary for follow on laboratory testing which may be completed at the contractor facilities (if able/applicable), or by the USG materials lab.

5.1.1.3 TH-57 M250-C20J Test, Teardown & Evaluation (TT&E) (CLIN 0X01) The Contractor shall perform M250-C20J engine test, as required, depending on the nature of the discrepancy as listed in paragraph 5.1.1.3. 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. If the engine fails to achieve minimum engine performance specification IAW Rolls-Royce M250-C20J, the Contractor shall identify necessary engine repairs that will return the engine to the Government in 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 Test, Teardown, and Evaluation of the M250-C20J engines via the Engine Transaction Reports (ETR) using the DECKETR. In the event the system is down or under maintenance period, 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.

Guidance may be obtained from the Commander Naval Air Forces Aircraft Engine Manager via the COR.

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

5.1.1.4 TH-57 Engine Repairs (CLIN X003)

The Contractor shall perform required M250-C20J engine depot level repair services IAW the Rolls-Royce commercial standards to include, but not limited to, Test, Teardown and Evaluation (TT&E), Mandatory CEB compliance and installation. 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.

The contractor shall request Beyond Economical Repair (BER) designation from USG for each M250-C20J Engine for which the work scope estimates for repair and overhaul exceeds 75% of M250 Engine replacement value provided by the contractor. The request shall include an estimate of labor and materials required to return the engine to RFI condition. Replacement value will be determined using the most current Rolls Royce Corporation’s catalogue pricing. If, after repair, the engine fails to achieve minimum engine performance specification, the engine shall be repaired and brought to RFI condition by the Contractor IAW Rolls-Royce Model 250-C20J.

Repair is defined as restoring an engine to RFI status following induction for discrepancies such as, but not limited to, failing power assurance tests/low power, leaking oil, making smoke, over-temp/hot start, over-speed, over-torque, metal in oil, foreign object debris (FOD), and vibration.

Overhaul of individual engine components that have reached life limits is not included in the scope of this PWS.

The Contractor shall maintain and provide logbooks for all repaired engines and components 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 repair of the 250-C20J engines via the ETR using the DECKETR. In the event the system is down or under maintenance period, 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. Guidance may be obtained from the Commander Naval Air Forces Aircraft Engine Manager via the COR.

The Contractor shall provide an engine test cell performance summary sheet for each engine returned that “ran” on the test cell IAW FAR Part 145.

5.1.1.5 TH-57 Engine Repairs - Over and Above (O&A) (CLIN 0X04, 0X05) The Contractor shall provide support to O&A requirements not previously defined 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 an O&AWork Request within 14 calendar days from the date of O&A determination to the COR IAW Appendix B, over & above Work Request (OAWR).

The Contractor shall perform additional required work as approved by the COR and IAW DFARS 252.217-7028 and Section H of this contract for efforts deemed warranted as over and above the normal repair requirements for those units already inducted under the applicable CLINs.

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 be responsible for the procurement of all material costs associated with engine repairs, engine assembly and engine container repairs.

Note: The engines and their shipping containers are Government Furnished Property (GFP).

After the Contractor has successfully assembled and passed the engine test, The Contractor shall submit the actual costs for all O&A work IAW CDRL A004 Engine deficiency report.

Airworthiness Directives and Service Bulletins (CLIN 0X04, 0X05) The Contractor shall incorporate Airworthiness Directives (AD) and Service Bulletins (SB).

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 Navy Fleet Support Team (FST).

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 Shipping Repaired TH-57 Engines and turnaround time (TAT) (CLIN 0X01) The Contractor is responsible for the packaging and shipping repaired TH-57 Engines back to NASWF, FL. The Contractor shall return RFI engines within a TAT of 100 calendar days beginning the first day the engine received by the contractor at NASWF, FL.

5.2 Qualifications/Certifications (ALL CLINS)

The Contractor shall maintain the Rolls Royce Corporation AMROC certification and FAA Part 145 certification (or equivalent approved by the FAA) or partner with a sub-contractor that possesses Rolls Royce Corporation AMROC certification and FAA Part 145 certification (or equivalent approved by the FAA).

5.3 Quality Control Program (ALL CLINS)

5.3.1 Quality Assurance

The Contractor must implement and maintain a QA program to support/ensure quality maintenance practices IAW FAR 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 USN aircraft. The Contractor is responsible for the safety and accountability of all its employees. 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.

7 CDRL DELIVERABLES (ALL CLINS)

TH-57 Sea Ranger – EXHIBIT A

CDRL Title PWS Paragraph

A001 Conference Minutes 4.6.1

A002 Shipping and Packaging Discrepancy Report 5.1.1.1

A003 Engine Repair Status Report 5.1.1

A004 Teardown Deficiency Report 5.1.1.2, 5.1.1.3, 5.1.1.4, 5.1.1.5, 5.1.1.6

A005 Cybersecurity Implementation Plan 4.8.1

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 CI Critical Information CLIN Contract Line Item Number COMNAVAIRFORINST Commander, Naval Air Forces Instruction COR Contracting Officer Representative DCMA Defense Contract Management Agency DCMA INST Defense Contract Management Agency Instruction DECKETR Decision Knowledge Engine Transaction Reporting 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 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 IPTL Integrated Product Team Lead KRACEn Kits, Recovery, Augmentation, Components, Engines LES Local Engineering Specifications MED Maintenance Engineering Directives NACI National Agency Check plus Written Inquiries NAMP Naval Aviation Maintenance Program NAVAIR Naval Air System Command NAVAIRINST Naval Air Systems Command Instruction NCIC National Crime Information Center O&A Over and Above OEM Original Equipment Manufacturer O-Level Organizational level OMM Operation and Maintenance Manual

OPNAV Office of the Chief of Naval Operations OPNAVINST Office of the Chief of Naval Operations Instruction OPSEC Operational Security PCO Procuring Contracting Officer PMR Program Management Reviews POC Point of Contact PWS Performance Work Statement QA Quality Assurance QAR Quality Assurance Representative RFI Ready-For-Issue RO Requirements Officer SB Service Bulletins SECNAV Secretary of the Navy SECNAVINST Secretary of the Navy Instruction SGTF Small Gas Turbine FADEC SOFA Status of Forces Agreement SSA System Safety Analysis TAT Turnaround Time TD Technical Directives TOCO Task Order Contracting Officer TPOC Technical Point of Contact TT&E Test, Teardown & Evaluation