F139 Spares RFI_ Statement of Work ).pdf

DRAFT

FA8609-23-F-0008

Section J, Attachment 1

17 May 2024

CUI

STATEMENT OF WORK (SOW)

FOR

F139 (PW 4062-3) ZERO-TIME SPARE ENGINES (CORE ONLY)

FOR

USAF AND FMS REQUIREMENTS

17 May 2024

PREPARED BY

AFLCMC/LPS

PROPULSION ACQUISITION DIVISION

TINKER AIR FORCE BASE, OKLAHOMA 73145

On Behalf of

AFLCMC/WLC

MOBILITY AND TRAINING AIRCRAFT DIRECTORATE

KC-46 DIVISION

WRIGHT-PATTERSON AIR FORCE BASE, OHIO 45433

DISTRIBUTION STATEMENT D - Distribution authorized to the Department of Defense (DoD) and U.S.

DoD contractors only (U.S. DoD contractors must be qualified with assigned duties in direct support of the KC-46 Tanker Modernization Directorate IAW AFI 61-204 AFGM2 and comply with all applicable contractual license requirements); Operational use, 19 April 2019. Other requests for this document shall be referred the KC-46 Tanker Directorate, 2590 Loop Road West, WPAFB, OH 45433-7142 and/or the Propulsion Acquisition Division, 2450 D Street (Bldg 20), Wright-Patterson AFB OH 45433-7629.

WARNING – This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et seq) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties.

Disseminate in accordance with provision of DoD Directive 5230.25.

DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

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VERSION CONTROL

VERSION DATE COMMENT

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Table of Contents

1.0 INTRODUCTION AND SCOPE

2.0 APPLICABLE DOCUMENTS

3.0 MODIFICATIONS, ENHANCEMENTS, and UPGRADE SUPPORT - F139 SPARE ENGINES

3.1 PW4062-3 Engine

3.3 Manufacturing Management Program

3.3.1 Bill of Material (BOM)

3.4 Contractor Furnished Fuel

3.5 Logistics

3.5.1 Comprehensive Engine Management System (CEMS)

3.5.2 Engine Item Unique Identification (IUID) Markings

3.5.3 Packaging, Handling, Storage, and Transportation (PHS&T)

3.5.4 Shipping of Spare Engines

4.0 TEST AND EVALUATION - PRODUCT ACCEPTANCE

4.1 Acceptance Test Plans and Acceptance Test Procedures (ATPs)

4.2 Acceptance Test Records ................................................................. Error! Bookmark not defined.

5.0 SYSTEMS ENGINEERING/PROJECT MANAGEMENT (SEPM)

6.0 PROGRAM MANAGEMENT

6.1 Contract Work Breakdown Structure

6.2 Integrated Master Schedule (IMS)

6.3 Cost and Software Data Reporting

6.4 Risk Management

6.5 Government Industry Data Exchange Program (GIDEP)

7.0 CONFIGURATION MANAGEMENT

7.1 Contract Change Proposal (CCP)

7.2 Specification Change Notice (SCN)

7.2.1 Specification Maintenance

7.3 Deviations and Waivers

8.0 DATA MANAGEMENT

9.0 RESERVED

10.0 RESERVED

11.0 RESERVED

12.0 RESERVED

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13.0 QUALITY ASSURANCE

13.1 Foreign Object Damage (FOD) Prevention Program

14.0 CONTINUED AIRWORTHINESS AND REGULATORY COMPLIANCE

15.0 SYSTEM SAFETY

16.0 ENVIRONMENTAL FACTORS/ENVIRONMENT SAFETY AND OCCUPATIONAL HEALTH (ESOH)

17.0 SECURITY

18.0 KC-46 INFORMATION TECHNOLOGY

19.0 RESERVED

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1.0 INTRODUCTION AND SCOPE

The KC-46A aircraft is equipped with two Pratt & Whitney (P&W) PW4062-3/F139 engines. The engine military designation is the “F139.” A KC-46A spare engine core is comprised of a Pratt and Whitney PW4062-3 engine. General capabilities/specifications of the KC-46A F139 engine include thrust per high-bypass engine of 62,000 lbs.; maximum speed of Mach 0.86; cruise speed of Mach 0.80; range of 6,385 NM; and service ceiling of 40,100 ft. The PW4062-3/F139 is a modified commercial engine which varies from the PW4062 in that it does not have thrust reversers installed. However, the PW4062- 3/F139 does have an increased thrust capability termed “thrust bump,” additional electro-magnetic/IR shielding, and a larger generator as compared to the PW4062.

This SOW defines the effort required to meet the USAF and FMS customer requirements for the production and delivery of 20 spare engines for the KC-46A Fleet (both for USAF and FMS Programs).

The USAF and FMS Programs will procure PW4062-3/F139 spare engine cores in the most current configuration, applicable by country, at the time of award.

Each spare engine shall be preserved and wrapped shipped to Tinker AFB where Engine Build Up (EBU) will occur making the spare engine Ready for Installation (RFI). All procurement of QEC components, EBU, Inlet Cowl, and Engine Trailer/Cradle will be procured separately. Also included in the requirements is the delivery of complete engine build data for each spare engine.

2.0 APPLICABLE DOCUMENTS

The below listed reference documents form a part of this procurement to the extent specified herein.

USG Documents Document Number Document Name Version and Date DoDM 5000.04 Cost and Software Data Reporting (CSDR)

Manual 4 Nov 2011, Incorporating Change 1, 18 Apr 2018

MIL-DTL-85470B Inhibitor, Icing, Fuel System, High Flash NATO Code Number S-1745

15 Jun 1999

MIL-PRF-25017H (w/ Amendment 1)

Inhibitor, Corrosion/Lubricity Improver, Fuel Soluble (NATO S-1747)

4 Aug 2011

MIL-STD-129R Military Marking for Shipment and Storage 18 Feb 2014, Incorporating Change 2, 27 Sep 2019

MIL-STD-130N Identification Marking of U.S. Military Property 17 Dec 2007, Incorporating Change 1, 16 Nov 2012

MIL-STD-881F Work Breakdown Structures for Defense Material Items

13 May 2022

MIL-STD-2073-1E Department of Defense Standard Practice for Military Packaging

23 May 2008, Incorporation Change 4, 22 Apr 2019

AFMC Form 158 Packaging Requirements 24 Apr 2015 AFMC Instruction 24-

Packaging, Handling, Storage, and Transportation Acquisition and Sustainment Product Support Instructions

21 June 2022

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Technical Order (TO) 00-25-254-1

Comprehensive Engine Management System (CEMS) Engine Configuration

1 May 2016

Technical Order (TO) 00-85-20

Engine Shipping Instructions 15 June 1989

AWB-330A Propulsion System Type Certification 12 Dec 2017 DD Form 250 Material Inspection and Receiving Report 1 Aug 2000 DD Form 1574 Serviceable Tag – Material no date available DD Form 2794 Cost and Software Data Reporting Plan 1 Nov 2016

OTHER

NIST SP 800-171 Rev.

Protecting Controlled Unclassified Information in Nonfederal Systems and Organizations

Feb 2020

Joint Aeronautical Commanders’ Group

(JAGG)

Aviation Critical Safety Item Management Handbook

16 Mar 2011

AF6500 SAE Manufacturing Management Program 13 Nov 2014 ASTM D1655-21c Standard Specification for Aviation Turbine

Fuels 1 Dec 2021

Contractor Documents Contractor #s* Prime Item Specification(s) *including the approved Specification Change Notices (SCN) No dates available

3.0 MODIFICATIONS, ENHANCEMENTS, and UPGRADE SUPPORT - F139

SPARE ENGINES

3.1 PW4062-3 Engine

The Contractor shall fabricate and/or procure parts, assemble, test, and deliver zero-time (new Life Limited Parts) F139 spare engines. Engines shall meet the requirements of the Prime Item/Engine Specification. The zero-time F139 spare engines shall be produced to the same standard as the engines produced for installation on KC-46 production aircraft. The Contractor shall produce and deliver all spare engines in accordance with P&W (OEM-managed) configuration at the time of award. Spare engines associated with option CLINs shall be configured IAW configuration at the time of exercising the option CLIN.

The Contractor shall deliver spare engine configuration data/records to the Government for each spare engine; the Government will be responsible for entry of spare engine data into the USAF G081 Mobility Aircraft Data Systems real-time database (Core Automated Maintenance System for Mobility (CAMS-

FM/G081).

CDRL A001, DI-MISC-80508B/T, Technical Report-Study/Services: F139 Spare Engines, Subtitle:

G081 Importable Excel File

CDRL A002, DI-MISC-80508B/T, Technical Report-Study/Services: F139 Spare Engines, Subtitle:

Vital Statistics Logbook (VSL)

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3.3 Manufacturing Management Program

The Contractor shall maintain manufacturing management.

3.3.1 Bill of Material (BOM)

The Contractor Shall maintain a high-level detail (Core) BOM for the F139 spare engines associated with this procurement.

3.4 Contractor Furnished Fuel

The Contractor shall furnish petroleum/fuel necessary for use in the performance of this contract for engine assembly and acceptance testing. The Contractor shall comply with American Society for Testing and Materials (ASTM) D1655-21c, Standard Specification for Aviation Turbine Fuels, with the following additives: Inhibitor, Corrosion/Lubricity Improver (CI/LI) (MIL-PRF-25017), Inhibitor, Icing, Fuel System, High Flash NATO Code Number S-1745 (FSII) (MIL-DTL-85470B), an approved antioxidant (AO) material listed in MIL-DTL-5624 or MIL- DTL-83133, an approved static dissipater additive (SDA) listed in MIL-DTL- 5624 or MIL-DTL-83133, a thermal stability improver additive as described in MIL-DTL-83133.

3.5 Logistics

3.5.1 Comprehensive Engine Management System (CEMS)

The Contractor reporting responsibilities are described in Technical Order (TO) 00-25-254-1, Comprehensive Engine Management System (CEMS) Engine Configuration. The Contractor shall:

• Gather all CEMS reporting data items for each new spare engine, sub-part/components, etc., and deliver the data electronically to the Government (IAW applicable CDRL/DID) at the time of spare engine DD-250 Certification and Delivery (for Government entry of data into the CEMS database: via CEMS Data Load File). The Contractor will not be required to access/enter engine data (initial load) into the CEMS Central Database (CDB) for spare engines associated with this

DO SOW.

• CEMS data provided by the Contractor shall include all hardware/components installed within each engine, to include, but not limited to: Configuration Item Identifier (CII), Work Unit Code, Item Nomenclature, Life Limited Part verification (Yes/No), Part Number, and Serial Number.

The “CEMS Data Load File” delivered by the Contractor shall be compatible with CEMS/D042 formats (see tailored CDRL item below).

CDRL A004, DI-MGMT-81324C/T, Comprehensive Engine Management System (CEMS) Reporting, CEMS Data Load File

3.5.2 Engine Item Unique Identification (IUID) Markings

The Contractor shall mark the engine data plate with IUID in accordance with MIL-STD-130N, Identification Marking of U.S. Military Property, or equivalent standard. Any currently IUID marked engine components shall be maintained for this program. The Contractor shall upload the IUID assigned numbers and information into the Government IUID Registry following the Using Service‘s guidance and procedures. The IUID shall contain, at a minimum: applicable Enterprise Identifier (EID), Serial Number, and Part or Identifying Number (PIN). IUID markings shall be visible during normal handling, be readable, withstand the specified environment and cleaning processes, and be as permanent as the service life of the unit or at least to the unit’s point of rebuild.

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All engines shall be delivered with their EECs marked on their Pb Sensor Inspection Plate with the “born-on” information of the sensors IAW Service Bulletin PW4ENG 73-221 for calendar time tracking per SB

EEC131-73-62.

3.5.3 Packaging, Handling, Storage, and Transportation (PHS&T) The Contractor shall be responsible for the preservation and packaging of all necessary components and engines for shipment IAW the Packaging Instruction specified on Air Force Materiel Command (AFMC) Form 158, Packaging Requirements. The Contractor shall follow packaging, handling, storage, transportation practices in accordance with applicable existing Technical Orders (TOs) and/or in accordance with MIL-STD-2073-1E, Standard Practice for Military Packaging. The Contractor shall place a special tag, DD Form 1574, Serviceable Tag - Material, inside the package along with the assembly as well as outside the package. In addition, all marking, and labeling of unit and shipping containers shall be in accordance with MIL-STD-129R, Military Marking for Shipment and Storage.

3.5.4 Shipping of Spare Engines

The Contractor shall prepare the preserved/wrapped spare engines for shipping, including preparing spare engines within protection-coverings (e.g. reusable protection bags) appropriate for mode(s) of shipping in accordance with MIL STD -2073-1E, Standard Practice for Military Packaging. The Contractor shall be responsible for shipment/transportation of USAF spare engines to designated CONUS locations.

The shipment/transportation of FMS spare engines to OCONUS locations will be the responsibility of the Government. The contractor shall transport engines IAW TO 00-85-20 (Engine Shipping Instructions), AFMCI24-201 (Packaging, Handling, Storage, and Transportation Acquisition and Sustainment Product Support Instruction), and Standards Practices Manual (Part Number 585005) Section 70-80-00 following all guidelines, AFI's, Technical Instructions, and other references mentioned therein.

4.0 TEST AND EVALUATION - PRODUCT ACCEPTANCE

the Contractor shall perform the level of test and evaluation required to ensure all spare engines associated with this procurement, will perform in their intended environment in support of the KC-46 weapon system. The Contractor shall adhere to FAA and military certifications, and Operational Safety, Suitability & Effectiveness (OSS&E) baselines.

4.1 Acceptance Test Plans and Acceptance Test Procedures (ATPs) The Contractor shall develop/update and maintain the Acceptance Test Plan for F139 spare engines.

The test plan defines the acceptance test, performance objectives, criteria, and detailed procedures for the acceptance of all F139 spare engines and associated components and articles that will be accepted and delivered to the Government.

5.0 SYSTEMS ENGINEERING/PROJECT MANAGEMENT (SEPM)

The Contractor shall perform any systems engineering and project management efforts applicable to the spare engines production.

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6.0 PROGRAM MANAGEMENT

6.1 Contract Work Breakdown Structure

The Contractor shall develop, deliver, and maintain a CWBS and a CWBS Dictionary in accordance with MIL-STD-881F, Work Breakdown Structures for Defense Material Items. The Contractor shall request and receive Government approval before making any changes to the CWBS and/or associated definitions impacting reporting level Work Breakdown Structure elements.

CDRL A006, DI-MGMT-81334D/T, Contractor Work Breakdown Structure

6.2 Integrated Master Schedule (IMS)

The Contractor shall develop, deliver, implement, and maintain an IMS that identifies the contracted F139 Spare Engine buy scope and external critical dependencies, such as P&W engine production and deliveries, test/verification activities, , DD-250 activities, and spare engine shipment-related information/timelines (examples only - not all inclusive). The Contractor shall map the schedule information to the CWBS.

CDRL A007, DI-MGMT-81861C/T, Integrated Program Management Data and Analysis Report, Integrated Master Schedule (IMS)

6.3 Cost and Software Data Reporting

The Contractor shall systematically collect and electronically report to the Cost Assessment Data Enterprise the actual contract costs and technical information based on the Office of the Secretary of Defense (OSD) Deputy Director Cost Assessment (DDCA) approved CSDR Plans in accordance with the Department of Defense Manual (DoDM) 5000.04, Cost and Software Data Reporting (CSRD) Manual.

The Contractor shall present its approach to satisfy the CSDR guidelines contained in DoDM 500.04, Cost and Software Data Reporting (CSRD) Manual, and the requirements in the OSD DDCA-approved CSDR Plan for the contract, DD Form 2794, Cost and Software Data Reporting Plan, and the related Resource Distribution Table.

CDRL A008, DI-FNCL-81765B/T, Contractor Business Data Report (DD Form 1921-3), Contractor Cost Data Reporting (CCDR)

CDRL A009, DI-FNCL-82162, Cost and Hour Report (Flex File), Contractor Cost Data Reporting

(CCDR)

CDRL A010, DI-MGMT-82165, Technical Data Report

CDRL A011, DI-MGMT-82164, Quantity Data Report, Contractor Cost Data Reporting (CCDR)

6.4 Risk Management

The Contractor shall execute a Risk Management Plan for this procurement.

6.5 Government Industry Data Exchange Program (GIDEP)

The Contractor shall participate in the GIDEP. The Contractor shall generate “alerts” when applicable, acquire “alerts” from GIDEP Operations Center (Naval Surface Warfare Center, Corona Division, Corona, CA 92878-8000), and take corrective action when “alerts” impact the spare engine production program.

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CDRL A016, DI-QCIC-80125B/T, Government Industry Data Exchange Program (GIDEP) Alert/Safe-Alert Report

CDRL A017, DI-QCIC-80126B/T, Government Industry Data Exchange Program (GIDEP) Alert Response

CDRL A018, DI-QCIC-80127A/T, Government Industry Data Exchange Program (GIDEP) Annual Progress Report

7.0 CONFIGURATION MANAGEMENT

7.1 Contract Change Proposal (CCP)

The Contractor shall propose non-technical contract changes using existing Government CCP processes.

CDRL A012, DI-ADMN-81401C/T, Contract Change Proposals (CCPs)

7.2 Specification Change Notice (SCN)

All specification changes generated under this contract shall be subject to Government approval and submitted as an SCN.

CDRL A013, DI-SESS-80643E/T, Specification Change Notice (SCN)

7.2.1 Specification Maintenance

The Contractor shall maintain all Prime Item Specifications. Spare Engines shall meet the requirements of the Prime Item Specification. The applicable specification(s) shall be revised upon incorporation of any technical SCNs.

All specifications and standards, including those published by both Government and Non-Government sources, explicitly cited in either the contract specification, Prime Item Fabrication Specification, Model Specification or as referenced in the specific contracts, all Specification Notices appended thereto, , shall be first tier references and mandatory for use to the extent called out therein. Lower tier references will be for guidance only and will not be contractually binding unless they are directly cited in this contract.

Specification and standards listed on engineering drawings are to be considered first-tier references.

7.3 Deviations and Waivers

The Contractor shall prepare requests for deviation and waivers using existing Government processes.

CDRL A014, DI-SESS-80640E/T, Request for Variance (RFV) CDRL A015, DI-SES-81732/T, Request for Waiver (RFW)

8.0 DATA MANAGEMENT

The Contractor shall implement data management procedures for this procurement.

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9.0 RESERVED

10.0 RESERVED

11.0 RESERVED

There will be no GFP/GFE under this procurement for spare engines.

12.0 RESERVED

13.0 QUALITY ASSURANCE

The Contractor shall continue to implement and maintain a quality assurance program.

13.1 Foreign Object Damage (FOD) Prevention Program

The Contractor shall maintain existing FOD Prevention Programs. The Contractor shall assure FOD Prevention is accomplished, and work areas maintained in a manner to prevent foreign objects from entering and remaining in product structure(s). The FOD Prevention Industry Guideline shall be used as a guide.

14.0 CONTINUED AIRWORTHINESS AND REGULATORY COMPLIANCE

The contractor will continue to maintain all current airworthiness and regulatory compliance associated with the KC-46A/F139 engine.

15.0 SYSTEM SAFETY

16.0 ENVIRONMENTAL FACTORS/ENVIRONMENT SAFETY AND

OCCUPATIONAL HEALTH (ESOH)

17.0 SECURITY

18.0 KC-46 INFORMATION TECHNOLOGY

19.0 RESERVED

7.3 Deviations and Waivers