FA7000-15-R-0002_Att_6.b._Task_order_0002_(CKC-135_TA).pdf

FA7000-15-R-0002

Section L, Attachment 6.b.

TASK ORDER 0002 WORK STATEMENT

ENGINEERING ANALYSIS ACTIVITIES IN AGING STRUCTURES:

C/KC-135 Teardown Analysis Program (Vertical Stabilizer)

1.0 BACKGROUND AND INTRODUCTION

1.1 Summary. The Center for Aircraft Structural Life Extension (CAStLE) at the United Stated Air Force Academy requires contractor support to conduct a destructive teardown analysis program on vertical stabilizer elements from KC-135 aircraft. The purpose of this program is to generate data to support an assessment of the current condition of the C/KC-135 fleet and to generate useful structural engineering data.

1.2 Basic Contract. This Work Statement describes only specific tasks and objectives applicable to this effort. The terms and conditions of the basic contract apply. Definitions of terms specific to this document or to the Aging Structures program can be found in the basic contract. Where specific tasks, terms, or conditions in this Task Order Work Statement and basic contract/contract clauses conflict, the basic contract governs.

1.3 Scope. The anticipated period of performance (PoP) for this Work Statement is 8-10 months—to be proposed by the Contractor and, if necessary, negotiated with the government prior to contract award.

1.3.1 Teardown Subjects. The structural teardown subjects of this task are the vertical stabilizer residual structure from two (2) previous KC-135 teardown analysis program aircraft.

For reference, the entire vertical stabilizer structure is depicted in structural skeletal form in Figure 1 and in a structural stiffener diagram in Figure 2. Comparison of the two diagrams illustrates the potential configuration differences possible in KC-135 vertical stabilizers. For example, note the additional height between WL 532.5 and WL 568.9 evident in Figure 2. An example of the subject structure is shown in Figure 3, Figure 4, and Figure 5. As noted in the caption the subject residual structure is indicated by the pink shading. Also noted in the captions are descriptions of the relevant region and view of the subject structure. Within the subject structure and as required by contractor processes used to execute CAStLE Protocols, the Contractor shall identify a sufficient number of teardown sections (TS) to perform the objectives of this Work Statement. In order to minimize the number of TS cuts through residual structure and thereby minimize the potential for loss of analysis data in the subject structure, the Contractor shall endeavor to minimize the number of TS. TS may be as large as permissible by the Contractor’s protocol processes.

Figure 1: KC-135 vertical stabilizer subject is depicted in Figure 1 in structural skeletal form.

Figure 2: KC-135 vertical stabilizer in structural stiffener diagram form.

Figure 3: Example of subject KC-135 vertical stabilizer structure, taken from the upper half left-side view of the residual structure, shown by pink shading.

Figure 4: Example of subject KC-135 vertical stabilizer structure, taken from the lower half left-side of the residual structure, shown by pink shading.

Figure 5: Example of subject KC-135 vertical stabilizer structure, taken from the lower half right-side of the residual structure, shown by pink shading.

1.3.2 Root Cause Analysis. The contractor shall perform detailed root cause analyses of 20 NDI indication sites selected by the Government Technical Lead (GTL) from the Contractor’s prioritized NDI indication list (reference paragraph 2.3.5).

2.0 DESCRIPTION OF SUB-TASKS

2.1 Sub-Task 1: Transportation. The Contractor shall transport the subject KC-135 vertical stabilizer structure from government storage in Ste. Genevieve, Missouri to the contractor’s site.

2.2 Sub-Task 2: Teardown Analysis Planning. The Contractor shall describe their processes to meet the requirements of CAStLE Teardown Analysis Protocols 1-5, 7 and 8 (solicitation Attachment 4) to accomplish the objectives of this Work Statement.

2.2.1 Vendor Qualification. The Contractor is required to use qualified personnel as defined by each applicable protocol. The Contractor shall propose a plan to ensure to the GTL that Protocol-specific requirements are met. Execution of the qualification plan shall include demonstration of vendor Protocol qualification to the GTL or other government designee. The Contractor qualification plan shall include provisions to audit protocol processes during the execution of this Work Statement. The Contractor qualification plan shall include provisions for qualification demonstration and audits of all vendors used by the contractor to perform protocol tasks in support of this Work Statement.

2.2.2 Protocol Execution Planning. The Contractor shall describe their process plan to meet the requirements of each protocol to achieve the teardown analysis execution objectives (reference Section 2.3) of this Work Statement on the subject structure. This plan shall address the following:

a. Defining TS to the GTL for approval as required by Contractor processes and Protocol 3 requirements.

b. Preventing/minimizing incidental damage to subject structure during the execution of TS extraction (Protocols 3), TS disassembly (Protocol 4), and part coating removal (Protocol 5) when preparing structure for nondestructive inspection (Protocol 7).

c. Ensuring that all data are recorded as required by Protocols 1-5, 7 and 8.

d. Ensuring the security and accurate location tracking of all teardown analysis subjects as required by Protocols 1-5, 7 and 8.

e. Ensuring the accurate tracking of protocol process status as required by Protocols 1-5, 7 and 8.

f. Prioritizing all nondestructive inspection (NDI) indications for recommendation to the GTL to select indications for root cause analysis which are of greatest interest to KC-135 fleet managers during the execution of (Protocol 8).

g. Handling methods to prevent unintentional damage to parts after NDI.

h. Transportation of teardown analysis subjects, if required, between protocols and protocol tasks.

2.3 Sub-Task 3: Teardown Analysis Execution. This task is the execution of the teardown analysis requirements. Analysis requirements are stated in paragraph 2.2, paragraph 2.3, and CAStLE Protocols 1-5, 7, and 8. Additional emphasis of these requirements is addressed in the following. The Contractor shall describe how their processes meet the requirements of this Task.

2.3.1 Teardown Section Extraction. The contractor shall remove Contractor defined TS from the subject structure per CAStLE Protocol 3. Contractor defined TS definition shall be documented via CAStLE Protocol 3 data requirements. As referenced in CAStLE Protocol 3 the Contractor shall prepare Teardown Analysis Program Section Identification Documents (TAPSID) which sufficiently describes to the GTL the plan for cutting the subject vertical stabilizer structure into TS. The TAPSIDs shall be submitted to and approved by the GTL prior to executing the cutting tasks of CAStLE Protocol 3.

2.3.2 Teardown Section Disassembly. The contractor shall separate each TS into the individual parts per CAStLE Protocol 4. The contractor shall remove all mechanical fasteners (e.g. rivets, bolts, and spot-welds) without causing any incidental damage to the part during the disassembly process. Incidental damage, in this case, shall be understood to include such damage events as dents/bends/creases, scratches/gouges, material removal via abrasives, unplanned cuts, misdrilled or double drilled holes, thermal modification of material properties, and microstructural damage to the surface of the metallic structure (e.g. etching). Per CAStLE Protocol 4, the contractor shall record incidental damage along with pre-existing damage (prior to CAStLE Protocol 4 execution) to the Government via the Teardown Data Management System

(TDMS).

2.3.3 Coatings Removal. In preparation for nondestructive inspection (NDI), the contractor shall remove all aircraft coatings, sealants, and corrosion protective systems from the disassembled aircraft parts per CAStLE Protocol 5 without causing incidental damage to the parts. Incidental damage shall be reported as described in the protocols.

2.3.4 Nondestructive Inspection (NDI). Under the supervision of an American Society of Nondestructive Testing (ASNT) Level III NDI Technician, an ASNT Level II (or higher) NDI technician shall perform NDI per CAStLE Protocol 7 on all disassembled aircraft parts that have undergone the coatings removal process. Certification from an organization equivalent to ASNT is acceptable upon written approval of the Government. Each part shall be inspected by the CVI and FPI techniques defined in Protocol 7. The Contractor will inspect 20 holes identified by the GTL via the eddy current or magnetic particle techniques defined in Protocol 7.

2.3.5 Root Cause Analysis. The Contractor shall prioritize NDI indications for consideration by the GTL for detailed root cause analysis, also known as failure analysis (FA), per CAStLE Protocol 8. The Contractor’s prioritization rubric shall favor those NDI indications which are most likely to be damage which is of interest to KC-135 structural fleet managers. The GTL shall have final authority on selection of NDI indications for this objective. The contractor shall conduct root cause analyses of the requisite number of selected NDI indication regions per CAStLE Protocol 8. The primary goals of this objective are to determine the root causes of the selected NDI indication regions and other data which may be of relevance to the C/KC-135 fleet managers.

2.3.6 Data Recording and Entry. The contractor shall upload all teardown data and protocol execution progress/status into the TDMS per CAStLE Protocol 1 and the TDMS-specific requirements in CAStLE Protocols 3-5, 7 and 8. In the event that TDMS is unavailable (e.g.

network outage, TDMS system maintenance, etc.), data shall be recorded manually by the contractor. Upon the restoration of the availability of TDMS, the manually-recorded data shall then be uploaded by the contractor into TDMS. The contractor shall accomplish the upload of all TDMS-specific Protocol data requirements prior to reporting status complete for any given objective.

2.3.7 Identification and Tracking. The contractor shall identify and track all structure from the subject aircraft per CAStLE Protocol 2.

2.4 Sub-Task 4: USAFA Cadet Projects. With the concurrence of the KC-135 USAF program office (obtained through CAStLE), cadet research projects may be derived from the CAStLE Protocol 7 and 8 tasks. In those cases, the contractor shall provide subject matter expertise on a limited basis to support such projects.

3.0 REQUIRED DELIVERABLES

3.1 Reports and Documents. In addition to the basic contract CDRL items the contractor shall deliver the following reports and documentation.

3.1.1 Data. The data generated during the course of the teardown analysis program in accordance with CAStLE Protocols 1-5, 7, and 8. These data for each objective under Section 2.3 shall be uploaded into TDMS prior to the contractor reporting the status of any given objective complete (reference Section 3.1.2). Quad charts and associated data generated by CAStLE

Protocol 8 (reference Section 2.3.5) shall be incrementally submitted to the GTL for approval upon completion.

3.1.2 Monthly status. The contractor shall report monthly completion status and projected production (“burn-down” charts) by relevant entity of CAStLE Protocol 3-5, 7 and 8. The relevant entity for Protocol 3 is TS. The relevant entity for Protocol 4, 5, and 7 is part. The relevant entity for Protocol 8 is indication.

3.1.3 Final report. A draft final report shall be delivered to the GTL for review 45 calendar days prior to the end of the PoP. The government shall have 30 days to provide comments for Contractor incorporation into the final report. (A006).

3.2 Aircraft Parts. All Government supplied aircraft TS, parts, failure analysis subjects and residual structure shall be retained by the Contractor in safe storage in accordance with the terms of the basic contract for teardown analysis program parts for the duration of the PoP.

4.0 GOVERNMENT FURNISHED PROPERTY

Teardown subjects are government property provided to the Contractor as de-militarized scrap. With the exception of the teardown analysis subjects, there will be no Government- Furnished Property (GFP). The contractor shall provide all equipment required for the execution of this task. The Contractor can have access to equipment in the USAF Academy CAStLE lab for execution of this task. Whereas cadet curricular needs take priority, CAStLE lab equipment use will be subject to availability based on cadet requirements. The Contractor will be expected to use, care for and prevent damage of equipment in accordance with manufacturer instructions.

5.0 REQUIRED SUPPORT

The Contractor shall describe the need for the use of each category of support to meet the Task requirements. Proposed costs should be included in the accompanying cost/price proposal (solicitation Attachment 3b).

5.1 Travel. Travel will be required in support of this Task Order. The offeror will propose travel appropriate to the Work Statement requirements for site visits, a kick-off meeting, technical interchange meetings, and program reviews

5.2 Transportation. The offeror will propose transportation appropriate to the Work Statement requirements.

5.3 Storage. The offeror will propose storage appropriate to the Work Statement requirements.

5.4 Materials and Other Direct Costs. The Government anticipates materials will be required to fulfill the Work Statement requirements. Provide necessary quantities and types of material proposed, as well as the purpose of each item and its sub-task association.