Draft SOW.pdf

STATEMENT OF WORK

Piston Aviation Fuels Initiative Material Compatibility Testing

March 2025

TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 REFERENCES

3.0 SCOPE

3.1 ACCESS AND USE OF INFORMATION

4.0 PROGRAM MANAGEMENT

4.1 POST-AWARD CONFERENCE

4.2 STATUS MEETINGS & TELECONFERENCES

4.3 FUEL HANDLING RETENTION AND DISPOSAL

4.4 SAMPLING AND ANALYSIS

5.0 CONTRACTOR SAFETY AND HANDLING

6.0 DELIVERABLES

6.1 ELECTRONIC DATA REQUIREMENTS

FOLLOWING IS A SUMMARY OF THE MATERIALS TESTING TO BE PERFORMED:

6.2 DELIVERABLES TABLE

6.3 FINAL REPORTS

7.0 FAA TEST PARTICIPATION AND INSPECTION

8.0 SHIPPING

1.0 Introduction

The Federal Aviation Administration (FAA), Fuels and Energy Section, ANG-E283, supports the FAA’s Piston Aviation Fuels Initiative (PAFI) and the Eliminate Aviation Gasoline Lead Emissions (EAGLE) programs. These programs lead the FAA’s research efforts to identify and authorize unleaded fuel replacements for current 100 octane low lead (100LL) aviation gasoline, the only remaining transportation fuel in the United States that still contains lead additives. In the 2024 FAA Reauthorization Act, Congress has set a goal for the FAA to transition industry to lead-free aviation fuels for piston-engine aircraft, by the end of 2030, without adversely affecting the safety of the existing fleet.

The Fuels and Energy Section requires testing services to evaluate materials compatibility of an unleaded candidate fuel in accordance with this Statement of Work (SOW) and attached PAFI Materials Test Plan (PAFI-MTP-002). This testing will support interim program milestone dates that will allow the FAA to achieve the overarching goal set by Congress.

2.0 References

The Contractor must comply with the requirements set forth in the documents identified in Table 1, or any versions that supersede, unless notified in writing by the CO.

TABLE 1

Reference Standards, Specifications, and other Documents

14 CFR Part 21 Certification Procedures For Products And Articles

14 CFR Part 22 General Reporting Instructions

14 CFR Part 23 Airworthiness Standards: Normal Category Airplanes

TSO-C80

FAA Technical Standards Orders for Aircraft Materials, Parts and Appliances: C- 80 Flexible and Oil Cell Material

MIL-DTL-6000D

Department of Defense: Detail Specification-Hose, Rubber, Aircraft, Fuel, Oil, Coolant, Water, And Alcohol

MIL-HDBK-510 Department Of Defense Handbook: Aerospace Fuels Certification

AMS-S-8802

Society of Automotive Engineers (SAE): Sealing Compound, Temperature Resistant, Integral Fuel Tanks And Fuel Cell Cavities, High Adhesion

AMS3276

Society of Automotive Engineers (SAE): Sealing Compound, Integral Fuel Tanks and General Purpose, Intermittent Use to 360°F (182°C)

Reference Standards, Specifications, and other Documents

AMS3277

Society of Automotive Engineers (SAE): Sealing Compound, Polythioether Integral Fuel Tanks and General Purpose, Fast Curing Intermittent Use to 360°F (182°C)

AMS3281

Society of Automotive Engineers (SAE): Sealing Compound, Polysulfide (T) Synthetic Rubber For Integral Fuel Tank and Fuel Cell Cavities Low Density (1.20 to 1.35 sp gr), for Intermittent Use to 360°F (182°C)

AS5127 Society of Automotive Engineers (SAE): Methods for Testing Aerospace Sealants

AS5127/1

Society of Automotive Engineers (SAE): Aerospace Standard Test Methods for Aerospace Sealants, Two-Component Synthetic Rubber Compounds

ASTMD412

ASTM International: Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers—Tension

ASTMD471

ASTM International: Standard Test Method for Rubber Property—Effect of Liquids

ASTMD2240

ASTM International: Standard Test Method for Rubbery Property – Durometer Hardness

3.0 Scope

The Contractor must provide all technical, engineering, operations, business, administrative, and other support required to conduct comparative compatibility testing of materials required for participating in the FAA’s PAFI Program.

This data will be used for the evaluation of an unleaded fuel for the PAFI program and fleet authorization. Use of this test plan generates data meeting the applicable requirements of 14 CFR Parts 23 and 33 or ASTM D7826 for material compatibility.

3.1 Access and Use of Information

Because of the highly sensitive nature of the information pertaining to proprietary aspects of this testing, all participants must execute a Non-disclosure Agreement (NDA) prior to being provided access to any information regardless of its form. In addition, the Contractor and their affiliates may be required to execute a NDA with the Fuels providers to which the FAA will not be responsible for nor a party to.

The Contractor must conduct all or some combination of the following test procedures per PAFI-

MTP-002.

Task 1 Hose Testing

MIL-DTL-6000

MIL-DTL-5593

Task 2 Bladder Testing TSO-C80

Task 3 Sealant Testing

Task 4 O-ring testing

Task 6 Fabric Testing

Task 7 Distribution Testing

Task 8 Composite Testing

Task 9 Filter/Coalescer Testing

Task 10 Vendor Supplied Materials Testing

Task 11 D7826 Testing

Rig Test Plans

Rig 1

Rig 4

Rig 5 Rig 9

4.0 Program Management

4.1 Post-Award Conference

The Contractor must participate in a pre-test conference that will be held within ten (10) business days after award. The purpose of the conference is to facilitate open communication, review the SOW and Materials Test Plan, answer questions, and assist both Contractor and the Government in achieving a clear and mutual understanding of all requirements.

The FAA is responsible for establishing the time, place and Contractor notification of the conference. At the discretion of the FAA, the conference may be virtual. If in-person, the FAA will travel to the Contractor’s facility. The FAA Contracting Officer Representative (COR) will act as the conference chairperson. In the event the COR is unavailable, the FAA will appoint a designee.

Within ten (10) business days after the post-award conference, the Contractor must provide the following to the FAA COR via email:

A list of key personnel, including email and mailing addresses and phone number.

Signed NDAs for all applicable staff.

A proposed schedule of the test activities including:

Planned locations for each test.

Planned start and end dates for each test.

Shipping addresses, phone numbers, and contact information for the government furnished equipment.

Shipping addresses, phone numbers, and contact information for test fuel delivery.

4.2 Status Meetings & Teleconferences

The Contractor must hold status teleconferences on a weekly basis, or as otherwise directed by the COR, to review overall project status to include, schedule, test activities and results, questions and issues arising from the testing, and other information. For these meetings, the FAA COR will act as Chairperson. If the FAA COR is unavailable, a weekly written status report detailing this information must be provided via email.

4.3 Fuel Handling Retention and Disposal

The Contractor will use test fuels as specified by the FAA for the performance of this work, including industry standard 100 octane Low Lead (100LL) and the unleaded test fuel. The unleaded test fuel will be provided at no cost to Contractor from either the fuel provider or the

FAA.

The Contractor must obtain industry standard Fixed Base Operator 100LL avgas, as well as any other test fluids specified to be used in performance of this testing.

Use of fuels during the test program requires the bulk handling and storage of experimental fuels.

The Contractor will ensure proper handling, storage and labeling of fuel storage vessels to appropriately segregate the two test fuels, 100LL and the unleaded test fuel, during testing.

Contractor personnel are required to use applicable Personal Protection Equipment (PPE) and follow safety requirements in accordance with all applicable regulations of the Safety Data Sheet (SDS). The SDS for the unleaded fuel will be provided by the FAA or the unleaded fuel provider.

The Contractor must provide a Fuel Handling Plan (FHP) to the FAA before receiving the test fuel(s) that complies with the fuel manufacturers recommendations on the proper safety, handling, and quality control of the test fuels. This includes, but is not limited to, proper cleaning and preparation of fuel storage containers/tanks, transfer vessels, and testing apparatus. The FAA will provide a copy of its FHP as a reference as to the form and content expected to be included in the Contractor’s FHP. The FHP must include procedures on cleaning and preparation of fuel storage containers/tanks and be approved by the FAA prior to the start of testing.

All fuel used in the testing must be stored in sealed stainless-steel, laboratory grade amber glass, or other containers that are approved by the FAA prior to the start of testing. The containers must be properly marked to indicate fuel designator and fuel formulation number. At the conclusion of testing, any remaining unleaded test fuels must be returned to the FAA at the address noted in Paragraph 8, the fuel supplier, or at the FAA’s request, disposed of in accordance with all local, state, and federal regulations. This includes fuel at subcontractor or partner locations. Shipping and/or disposal costs for the unleaded test fuels only, will be reimbursed as a disposal fee in accordance with the requirements herein. Disposal of candidate test fuels may only occur with prior written approval by the FAA COR and proof of disposal must be provided.

4.4 Sampling and Analysis

The Contractor will be responsible for collecting, packing/labeling, and shipping of fuel samples, and hazardous materials (hazmat) shipping as applicable. The Contractor must comply with all local, state, and federal regulations covering the shipping of hazmat.

The Contractor will be provided a SDS for the unleaded fuel to be tested. The Contractor must not conduct any chemical or physical property analysis of its own on unleaded fuels samples, in accordance with the NDA provisions of this contract.

All analysis of fuel samples will be completed by the FAA at no cost to the Contractor.

5.0 Contractor Safety and Handling

Due to the potential deviations from traditional petroleum chemistry, it is important for test facilities to have a copy of the health and safety information provided with the samples. While the actual formulations are proprietary and the testing organizations do not require specific blending information, the following information is required. Information relative to the specific fuels will be provided by the FAA.

A SDS or Material Safety Data Sheet (MSDS) sufficient for shipping samples including a 24-hour emergency contact number.

The Contractor must require the use of appropriate PPE, whether standard or non-standard. Standard PPE is that used for current petroleum products, including but not limited to, nitrile gloves, eye protection, and laboratory coats or aprons.

The Contractor has the right to require additional information for any item to ensure safe handling. It is the sole responsibility of Contractor to determine whether the provided SDS or MSDS are sufficient for the safe handling and disposal of the fuel and fuel contaminated materials.

The Contractor must comply with all local, state, and federal regulations for storage, distribution, or disposal of test fuels. This includes any special segregation, any disposal incompatibilities (materials with which the test fluid should not be mixed), or special handling.

6.0 Deliverables

All data, analysis results, and associated information (collectively known as “data”) gathered by the FAA during the performance of this contract will be the sole property of the FAA.

6.1 Electronic Data

All deliverables must be submitted electronically to the COR unless otherwise specified. The FAA system will accept attachments up to 25mb in size per email message. Electronic files will be in a format compatible with MS Office 365 (Word, Excel, PowerPoint). General graphic data (charts, plots, etc.) within MS Word or PowerPoint files must be in 24 bit color. Scanned copies of documents where originals were hardcopies, including logbooks, inspection forms, etc. must be provided in Adobe Acrobat (.pdf) format, version 1.7 or later, at a minimum resolution of 600dpi in color if the original document contained colors or black and white if the original documents were black and white only. Photographs or other still images must be JPEG format with a minimum resolution of 3032x2008 (6 Megapixel) and either a 4:3 or 16:9 aspect ratio.

Video files must be in MP4 format with either a 4:3 or 16:9 aspect ratio and at a resolution of 720p or higher. All photographs and video recording must show a date and time stamp automatically recorded by the camera. The Contractor may propose alternative file formats and/or resolutions subject to FAA acceptance.

6.2 Requirements

Following is a summary of the materials testing to be performed:

Task 1 Hose Testing

Execute compatibility screening of MIL-DTL-6000 Hose, Rubber, Aircraft, Fuel, Oil, Coolant, Water, And Alcohol and MIL-DTL-5593 Hose, Aircraft, Low Pressure Air and Vacuum, Flexible, related to determining swell characteristics, and changes in swell and tensile/elongation properties following fuel exposure.

Task 2 Bladder Testing

Execute compatibility screening of specified fuel bladder construction related to degradation and delamination of the internal lining following fuel exposure in compliance with applicable parts of FAA TSO-C80 and ASTM D7826.

Task 3 Sealant Testing

Execute compatibility screening of specified integral fuel tank sealants related to changes to tensile/elongation, volume swell and peel strength properties following fuel exposure.

Specified materials are provided in PAFI Materials Compatibility Test Plan PAFI-MTP-002 Rev 0 dated 15 May 2024, Appendix D.

Task 4 O-ring testing

Execute compatibility screening of specified nitrile, fluorosilicone, and fluorocarbon elastomers in the form of O-rings, related to changes in hardness, tensile/elongation, volume change and compression set following fuel exposure. These materials are in addition to the full materials list specified in ASTM D7826. Specified materials are provided in PAFI Materials Compatibility Test Plan PAFI-MTP-002 Rev 0, dated 15 May 2024, Appendix E.

Task 6 Fabric Testing

Execute comparison testing of fabric tensile/elongation of specified fabric systems following fuel exposure. Specified materials are provided in PAFI Materials Compatibility Test Plan PAFI-MTP-002 Rev 0 dated 15 May 2024, Appendix G.

Task 7 Distribution Testing

Execute comparison testing of physical properties and long-term fill impacts of specified manufacturers of large distribution hoses. Specified materials are provided in PAFI Materials Compatibility Test Plan PAFI-MTP-002 Rev 0 dated 15 May 2024, Appendix H.

Task 8 Composite Testing

Execute comparison testing of specified resins, adhesives, foam cores, and fabrics used for composite structure construction. Specified materials are provided in PAFI Materials Compatibility Test Plan PAFI-MTP-002 Rev 0 dated 15 May 2024, Appendix I.

Task 9 Filter / Coalescer Testing

Execute comparison testing of filter elements, coalescer elements, housings, and fuel tank coatings used in distribution systems. Specified materials are provided in PAFI Materials Compatibility Test Plan PAFI-MTP-002 Rev 0 dated 15 May 2024, Appendix J.

Task 10 Vendor Supplied Materials Testing

Execute comparison testing of vendor supplied materials used by original equipment manufacturers. Specified materials are provided in PAFI Materials Compatibility Test Plan PAFI-MTP-002 Rev 0 dated 15 May 2024 Appendix K.

D7826 Testing

a. The list of integral fuel tank sealants includes a low strength access panel sealant and a liquid Buna-N topcoat which have material specific variations to the described required testing. Differences are provided.

Rig Test Plans

Rig 1, 4, 5, and 9

6.3 Deliverables Table

Test / Task Contractor deliverables

Applicable to all Tasks and Tests

Gantt Chart showing projected timeline and milestones updated every other week after contract award until contract completion All Deliverables and Test Results identified in PAFI-MTP-002 applicable to that task or tests respective section.

Proof of Specimen Preparation and Conformity to PAFI-MTP- One Test Results Report Per Each Test / Task including data, observations One Table per Test / Task graphically showing test results, compliance to pass / fail criteria as applicable, and actual test results

Task 1 hose testing

Pre and post test exposure measurements per pafi-mtp-002 section 12 Pre and Post Test Calculations per PAFI-MTP-002 Section 12 Pre and Post Test Sample pictures Exposure Pictures All additional Deliverables and Test Results identified in PAFI- MTP-002 Section 12

Task 2 bladder testing tso-c80

Pre and post test sample pictures Pre and Post Test Measurements Post-Test fluid nonvalitule gum residue ASTM D381 Exposure Pictures

Task 3 sealant testing

Pre and post test sample pictures Pre and Post Test Measurements Post-Test fluid nonvalitule gum residue ASTM D381 Exposure Pictures

Task 4 O-ring testing

Pre and Post Test Sample Pictures Pre and Post Test Measurements Post-Test fluid nonvalitule gum residue ASTM D381 Exposure Pictures

Task 6 fabric testing Pre and post test sample pictures Pre and Post Test Measurements Post-Test fluid nonvalitule gum residue ASTM D381

Exposure Pictures

Task 7 distribution testing

Pre and post test sample pictures Pre and Post Test Measurements Post-Test fluid nonvalitule gum residue ASTM D381 Test Set Up Pictures Pictures of leaks, seeps, slippage, internal hose condition, or any issues / failures

Task 8 composite testing

Pre and post test sample pictures Pre and Post Test Measurements Test Set Up Pictures Pictures of leaks, seeps, slippage, internal hose condition, or any issues / failures

Task 9 filter / coalescer testing

Pre and post test sample pictures Pre and Post Test Measurements Test Set Up Pictures Water Reaction Test Results per ASTM D1094

Task 10 vendor supplied materials testing

General deliverables Pre and Post Test Sample Pictures Pre and Post Test Measurements Test Set Up Pictures

D7826 testing

General deliverables Pre and Post Test Sample Pictures Pre and Post Test Measurements Test Set Up Pictures

Rig test plan 1 Requirements and deliverables per pafi-rtp-1 Rig test plan 4 Requirements and deliverables per pafi-rtp-4 Rig test plan 5 Requirements and deliverables per pafi-rtp-5 Rig test plan 9 Requirements and deliverables per pafi-rtp-9

6.4 Final Reports

After completion of each of the individual material tests (test sections) in the MTP, the Contractor must provide a separate final report for that respective test section. Each report must include the data, findings, analysis, and conclusions specific to one unleaded test fuel versus 100LL and/or other baseline test fluids. The report must not contain any information on more than one (1) test fuel.

The report must be comprised of research documents detailing all aspects of test procedures according to their ASTM practices and procedures. Test results must include test dates, test articles, test participants, and test results for each test activity and details of exceptions or test thresholds that could not be achieved. Each photo must include a specimen identifier such as a story board or label that includes delineating and identifying information such as fuel type, date, and material. Other information may be included in the label at the discretion of the Contractor such as soak time or sample number. The reports must also provide a conclusion of whether the tests were compliant with the provided pass/fail criteria.

The Contractor must provide a draft report within thirty (30) calendar days at the conclusion of testing of the specific material section. The FAA will review and provide comments within thirty

(30) calendar days of receipt. The Contractor must submit final reports within thirty (30) calendar days of the FAA’s comments.

It is the sole responsibility of the Contractor and their sub-contractors to ensure compliance with all applicable local, state, and federal laws pertaining to the safe handling and disposal of the test fuels, oils, and parts exposed to same.

The Contractor must ensure that appropriate fire prevention and extinguishing methods are followed as required.

The Contractor must ensure there is adequate electrical/static discharge protection, e.g., standard grounding, or better as required.

7.0 FAA Test Participation and Inspection

All testing, plans, schedules, scope, and efforts must be coordinated with the FAA COR.

The Contractor must provide unrestricted access to the FAA of activities under this SOW.

Access may involve participation and inspection of all aspects of test preparation, fuel handling, testing performed, data collection, analyses and other activities performed in support of this effort. The Contractor agrees to provide access and test related information requested by the FAA COR. The Contractor must provide the FAA COR with ten (10) business days advance notice of each test segment to allow the FAA time to coordinate its participation and/or observation of the test.

8.0 Shipping

The Contractor will be responsible for all fuel samples shipped until received at the final destination. Shipping addresses are as follows:

Federal Aviation Administration William J. Hughes Technical Center for Advanced Aerospace ANG-E283 Bldg. 211 Atlantic City, NJ, 08405

When required for the FAA to ship items to the Contractor, the Contractor must provide a shipping address and POC.