B.4.C PWS,ESN 876566 Combustion Chamber Replacement.pdf

U.S. Marshals Service (USMS) Justice Prisoner and Alien Transportation System (JPATS) CFM56-7B24/B1 Engine Serial Number

(ESN) 876566 Combustion Chamber Replacement Performance Work Statement

Original Revision

December 29, 2022

Table of Contents

1. General

2. Contract Type

3. JPATS Responsibilities

4. Contractor Responsibilities

4.1. Project Milestones

4.1.1. Engine Transportation Stand Delivery Date

4.1.2. Engine Pickup Date

4.1.3. Engine Induction Date

4.1.4. Engine Maintenance Completion Date

4.1.5. Engine Delivery Date

5. Place of Performance

6. Period of Performance

7. Warranty

8. Contract Administration Data

9. Right to Inspect / Audit

10. Deliverables

10.1. Daily Status Report

10.2. Accruals

10.3. Invoice

10.4. Engine Records

10.4.1. Post Maintenance Delivery Records

10.4.2. Mini Pack

11. Maintenance Requirements

12. Performance Standards

12.1. Assessing Performance

1. General

The United States Marshals Service, Justice Prisoner and Alien Transportation System (JPATS) has a requirement for the replacement of a cracked combustion chamber on a CFM56-7B24/B1 Engine bearing Engine Serial Number (ESN) 876566.

Engine specifications are as follows:

CFM56-7B24/B1 Engine; ESN 876566; Time Since New (TSN) 15,534.7; Cycles Since New (CSN): 21,053. Reference Section 11 for the list of maintenance requirements.

The engine maintenance and logistics efforts associated with this Performance Work Statement (PWS) must be adequately planned, staffed, and supervised by the Contractor to ensure all work schedules and maintenance activities are optimized.

Reference Section 4.1 for the list mandatory of Project Milestones.

At this time, it is not known where the aircraft will be located for the engine removal and reinstallation. JPATS anticipates awarding a contract for the aircraft’s heavy maintenance check, through a competitive acquisition, that will be performed concurrently with the engine combustion chamber replacement.

2. Contract Type

The Government anticipates awarding a firm-fixed price for the tasks listed in Section 11, Items 1 – 15. All Non-Routine discrepancies will be reviewed by the JPATS Contracting Officer’s Representative (COR) and approved utilizing a Time & Materials basis.

3. JPATS Responsibilities

As soon as practical after the award of the aircraft’s heavy maintenance check, JPATS will notify the Contractor of the aircraft’s location to ensure the Project Milestones refenced in Section 4.1 are met.

JPATS will ensure the engine is preserved and ready to be shipped to the Contractor’s facility on October 30, 2023.

JPATS will provide a current Life Limited Parts (LLP) Status Sheet and the current status of all FAA issued Airworthiness Directives.

A JPATS Contracting Officer’s Representative (COR) will be available and / or on-site for the duration of the combustion chamber replacement to ensure compliance with this Performance Work Statement (PWS) and to evaluate the repair of non-routine discrepancies.

4. Contractor Responsibilities

The Contractor will perform all maintenance requirements listed in Section 11 and complete all maintenance records documentation in accordance with the Contractor’s FAA Approved Repair Station Quality Control Manual.

The Contractor will appoint a point of contact (POC) for the JPATS Contracting Officer (CO) and COR.

The Contractor will provide written notification to the JPATS CO prior to subcontracting any portion of the maintenance effort to outside organizations or individuals.

The Contractor will notify the JPATS COR if a discrepancy (non-routine) is discovered during the performance of the inspections or maintenance. The Contractor will provide the CO with an estimated cost for the repair(s) and an estimated timeline for the repair(s) on a daily basis, utilizing a status sheet (contractor format). After approval is obtained to correct or repair the discrepancy, the Contractor will purchase any materials, supplies, and / or parts from an FAA approved vendor (all parts must be accompanied with an appropriately completed FAA Form 8130-3). Note: JPATS reserves the right to utilize JPATS owned spare parts or procure the required parts through the normal JPATS’ procurement process.

The Contractor will adhere to applicable statutes and regulations as prescribed by the Occupational Safety and Health Administration (OSHA), the Federal, State and Local Environmental Protection Agency (EPA), the National Fire Protection Agency (NFPA), and the Federal Aviation Administration (FAA).

The Contractor will provide all common tools, special tools, test sets and equipment, ground support equipment, “consumables”, and “free stock” such as grease, lubricants, rags, common hardware, etc.

The Contractor will purchase, store, use, and dispose of all hazardous materials (HAZMAT) associated with the maintenance of the engine, support equipment, and facilities in accordance with federal, state, and local statutes.

The Contractor will perform typical logistics tasks associated with the specified checks and inspections such as material and parts receiving, receiving inspections, identifying and reporting suspected unapproved parts (SUP), packing, crating, shipping, materials handling and storage, and shelf-life management.

The Contractor will perform all maintenance documentation to include JPATS historical logbooks for the engine as well as the FAA Form 337 for major repairs / alterations.

The Contractor is required to ensure all CAMP Task Cards, Logbook documentation, and Airworthiness Release procedures are performed in accordance with the Contractor’s FAA Approved Repair Station Quality Control Manual.

The Contractor will be responsible for the repair or replacement of any Government Furnished Property (GFP) that is damaged or destroyed by acts of negligence by the Contractor.

The Contractor will complete and return Section 11 to the JPATS Contracting Officer.

4.1. Project Milestones

The following project milestone are imperative to ensure a timely return to service of JPATS aircraft after the completion of the engine combustion chamber replacement. The engine combustion chamber replacement is being done concurrently with an aircraft heavy maintenance check therefore the engine delivery date must align with the aircraft return to service date. The Contractor must ensure all efforts are made to maintain the Project Milestones listed below and immediately notify the JPATS COR of any anticipated schedule delays.

4.1.1. Engine Transportation Stand Delivery Date

The required delivery date for the OEM Approved Engine Transportation Stand is October 23, 2023. Note: OEM Approved Engine Transportation Stand may be delivered as early as October 17, 2023.

4.1.2. Engine Pickup Date

The required pickup date for the engine is October 30, 2023.

4.1.3. Engine Induction Date

The required induction date for the engine is not later than November 2, 2023.

4.1.4. Engine Maintenance Completion Date

The required engine maintenance completion date, including test cell run, is not later than November 23, 2023.

4.1.5. Engine Delivery Date

The required engine delivery date is not later than November 27, 2023.

5. Place of Performance

All work will be performed at the Contractor’s Title 14 CFR Part 145 Certificated Repair Station located within the contiguous United States.

6. Period of Performance

JPATS anticipates a 21-calendar day period of performance with an induction date of not later than November 2, 2023 and a delivery date of not later than November 27, 2023. Reference Section 4.1 for a list of Project Milestones.

7. Warranty

The Contractor will provide the Government a copy of their standard commercial warranty.

8. Contract Administration Data

Only warranted Contracting Officers are authorized to issue and modify Government contracts, approve changes in any terms and conditions in a contract, or obligate funding. If the Contractor makes any changes at the direction of any person other than the Contracting Officer, the change will be considered to have been made without authority and no adjustment will be made to the contract to cover any increase in costs that may result.

9. Right to Inspect / Audit

The Government reserves the right to inspect / audit the Contractor’s facility along with their current maintenance processes and procedures prior to delivering the engine for services. The Government must ensure the Contractor is providing services in accordance with their Title 14 CFR Part 145 Repair Station Certification.

The Government may terminate the contract if it has reason to believe the Contractor is not providing services in accordance with their certificate.

10. Deliverables

10.1. Daily Status Report

The Contractor is required to provide a Daily Status Report. The Daily Status Report must include, as a minimum, a comprehensive list of the following:

• Number of personnel assigned to perform the repair,

• The previous day’s maintenance activities,

• Any additional inspection findings,

• The current day’s planned maintenance activities,

• Outstanding parts,

• Repairs that require engineering assistance, and

• Any anticipated delivery delays.

10.2. Accruals

The Contractor must provide JPATS with a twice weekly accrual of all costs incurred as part of the maintenance visit.

10.3. Invoice

The Contractor must submit all invoices to the address designated in the contract to receive invoices, and provide a copy to the CO and the COR, within thirty (30) days after the completion of the heavy maintenance visit.

10.4. Engine Records

10.4.1. Post Maintenance Delivery Records

At the completion of the engine repair, the Contractor must provide a physical and electronic copy (PDF Format) of the following documents:

• FAA Form 8130-3

• FAA Form 337

• Life Limited Parts (LLP) Status

• Current Status of Airworthiness Directives

• Borescope Report

10.4.2. Mini Pack

The Contractor must ensure all engine records and all original parts certification documentation are mailed to JPATS within thirty (30) days after the completion of the repair. As a minimum, the Mini Pack must include the following documents:

• FAA Form 8130-3

• FAA Form 337

• Life Limited Parts (LLP) Status

• Current Status of Airworthiness Directives

• Engine Test Cell Data

• Borescope Report

• QEC Inventory Report

The Contractor must provide an electronic copy (PDF Format) of all Engine maintenance records completed during the repair.

The Contractor must provide a copy of the full gas path video borescope after the completion of engine test cell run.

11. Maintenance Requirements

Task Number

Sub- Task Service Firm Fixed

Price

Provide OEM Approved Transportation Stand with casters to the Aircraft Repair Station on October 23, 2023. Note: OEM Approved Transportation Stand may be delivered as early as October 17, 2023.

Perform all Logistical Transportation Requirements to Transport ESN 876566 to Contractor’s 14 CFR Part 145 Repair Station on October 30, 2023.

3 Perform Full Gas Path Video Borescope Upon Receipt of Engine and Notify JPATS of Findings.

Perform Engine, Major Module, Minor Module, and Parts Inspection Utilizing ESM 72-00-00 Special Procedure 010 and Special Procedure 020.

Replace Damaged Combustion Chamber, with an Overhauled Combustion Chamber P/N:

1968M41G03, and Overhaul All Fuel Nozzles (or Replace with a Complete Set of Overhauled Fuel Nozzles) In Accordance With ESM 72-XX-XX utilizing ESM 72-00-00 Special Procedure 010 and Special Procedure 020. Note: JPATS Must Review and Approve Fuel Nozzle Flow Match Patterns Prior to Installation; Flow Pattern Must Not Have More Than 3 PSI Difference.

6 Perform AD 2018-26-01 Paragraph (g)

Perform Detailed Inspection of the Engine Inlet and Fan Blades by Performing Boeing Task Card 72- 020-02-01.

8 Lubricate Engine Fan Blades Dovetail by Performing Boeing Task Card 72-025-02-01.

9 Perform BLADIS / BLAMAP For Proper Redistribution of Fan Blades.

10 Perform VSV and VBV Static Rigging.

11 Perform Resistance Check of EGT Probes.

12 Perform Engine Test Cell Run per ESM 72-00-00 Test 002/003 and Test 009.

13 Perform Full Gas Path Video Borescope After Engine Test Cell Run.

14 Perform Engine 365 Day Preservation.

Perform all Logistical Transportation Requirements to Transport ESN 876566 from Contractor’s 14 CFR Part 145 Repair Station to Aircraft Repair Station.

12. Performance Standards

JPATS will primarily utilize the Contractor’s existing Quality Assurance System under Federal Acquisition Regulation (FAR) 12.208, Contract Quality Assurance, but will also assess the Contractor’s performance using the COR and the Performance Standards referenced in Section 12.1.

12.1. Assessing Performance

JPATS will utilize the table below for assessing performance of the Contractor.

The table includes the PWS Section Number, Performance Standard, Acceptable Quality Level, and Monitoring Method.

PWS Number Performance Standard

Acceptable Quality Level

Monitoring Method

Engine Maintenance

Requirements in Section 11 Completed

100%

Review of daily status report, COR oversight and delivery of engine.

Unscheduled (non-routine) Maintenance Requirements

Completed

100%

Review of daily status report, COR oversight and delivery of engine.

Appropriate Maintenance

Record Documentation

100%

Periodic review of engine maintenance record documentation.

Following Logistics Support Activities for the

Acquisition of Parts and Materials

100%

Periodic review of documentation and spot-check adherence to policies.

4.1.1 – 4.1.5 Delivery Schedule 100%

Observing all Project Milestones listed in Section

4.1.1 through

4.1.5.