PWS.pdf

PERFORMANCE WORK STATEMENT

(PWS)

For

Application of PWA 46 Tungsten Carbide Coating – LW-IN40

F100-PW-100(2), -220, & -220E –

1st, 2nd & 3rd

Compressor In-let Fan Rotor Blades

29 July 2013

PREPARING ORGANIZATION: 76 PMXG TINKER AFB OK 73145

1 SECTION I – Description Of Services.

1.1 The Contractor shall apply proprietary coating PWA 46 (Hardface) on Mid-span of the F100-PW-220/220E 1st, 2nd, and 3rd Stage Compressor In-Let Fan Rotor Blades.

1.1.1 The Contractor shall provide all required labor, direct material, parts, facilities, test equipment, and services, to accomplish repair of the Mid-span of the F100-PW- 220/220E 1st, 2nd, and 3rd Stage Compressor In-Let Fan Rotor Blades.

1.1.2 All blades will be shipped to the contractors in sets. The part numbers on the blades are for each, and two of the same part numbers make a set. The Contractor shall invoice via Wide Area Workflow (WAWF) using the set part number (PN) and national stock number (NSN) as follows:

F100-PW-220/220E

1st Stage PN 4081931 two each make PN 4081941, NSN 2840-01-503-0962NZ(Set) 2nd Stage PN 4081972 two each make PN 4081982, NSN 2840-01-503-0963NZ(Set) 3rd Stage PN 4084013 two each make PN 4084093, NSN 2840-01-434-6916NZ(Set)

1.1.3 76 PMXG will perform all requirements up to the application of PWA 46 to include peening on the airfoil and midspan. The contractor shall not perform repairs on the F100 fan blades other than those requirements stated in the PWS Any and all repairs after the contractors application of PWA 46 will be performed by 76 PMXG (i.e. airseals, anti-galling, and moment weighing). The contractor shall clean the blades IAW SPOP 18.

1.1.4 The Contractor shall ensure all requirements in this PWS are accomplished IAW the latest versions of the documents listed in PWS paragraph 1.2 if it does not impact cost and delivery schedules or if a conflict does not arise in implementation of the new procedures. If any of the preceding conditions occur, a written evaluation, along with specific backup data and estimated cost data for those changes which impact the Contractor’s performance shall be provided to the Procurement Contracting Officer (PCO) within ten (10) workdays after receipt of an updated publication. The Contractor shall not incorporate these publication changes until approved by the PCO. In the event there are conflicts between two or more referenced documents, the Contractor shall provide written evaluation, along with specific backup data to the PCO within ten (10) workdays after knowledge of the conflict. Resolution of the conflict will be provided by the PCO. In addition, the contractor shall immediately implement those publication changes that result in no change in contract price or delivery or have no conflicts.

1.2 Government Documents.

1.2.1. The Contractor shall obtain the forms and publications expressly required to perform the work in this contract via internet at www.e-publishing.af.mil. In the event that a form or publication is not available online, the 76 PMXG will provide the form, instruction, or publication to the Contractor upon written request (e-mail is acceptable) by the Contractor. In the event that laws, regulations, Technical Orders, Air Force Instructions, Air Force Material Command Instructions change during the term of this contract, the Contractor shall comply as such changes come into effect as required in

1.1.2 above.

1.2.2 USAF Technical Orders.

Publication Number Title Basic Date Latest

Chg Number

Latest Chg Date

33B-1-1 Nondestructive Inspection 1Oct1997 3 1Mar2000

1.2.3 Industry Documents.

1.2.4. Prattt & Whitney Documents.

Publication

Number Title Basic Date Latest

Chg Number

Latest Chg Date

TO 2J-F100-13-6

WP 334 00

TECHNICAL PROCEDURES -- BLADE,

COMPRESSOR ROTOR (STAGES 1

THRU’ 3)

INSPECTION

ENG, MOD F100-PW-100(3), -200,-220 & -

220E (PRATT & WHITNEY)

01 Aug 2005 40 01 Aug 02’

TO 2J-F100-13-6

WP 417 00

TECHNICAL PROCEDURES –BLADES,

COMPRESSOR ROTOR (STAGES 1 THRU

3) – REPAIR

ENG MOD F100-PW-100(3),-200, -220 &

220E (PRATT & WHITNEY)

01 Aug 2005 39 01 May 02’

T.O 2J-F100-13-2

WP 004 00

TECHNICAL PROCEDURES

INLET/FAN MODULE – SCHEDULED

MAINTENANCE

ENG MOD F100-PW-100(3) & 200 (PRATT

& WHITNEY)

1 May 1992 49 1 Aug 05’

TO 2-1-111 STANDARD MAINTENANCE

PROCEDURES P&W AIRCRAFT

ENGINES

15 Feb 1990 43 15 Sep 05’

Publication Number Title Basic Date

Latest Chg Number

Latest Chg Date

ISO/ANSI/ASQC

Q9001:

Quality Systems – Model for Quality Assurance in Production, Installation and Servicing

2008 N/A N/A

1.3 General Requirements.

1.3.1 Compliance with Laws and Regulations.

The Contractor shall be knowledgeable of and comply with all applicable Federal, State, and Local laws, regulations, and requirements regarding environmental protection. In the event environmental laws and regulations change during the term of this contract, the Contractor shall comply with such laws as they come into effect.

1.3.2 Quality System Requirements

The Contractor shall develop and maintain a quality management system in compliance with ISO/ANSI/ASQ Q9001:20008, AS9100, NATO AQAP 2070 or equivalent Quality systems – Model for quality assurance in production, installation and servicing, as a minimum. The Contractor shall design their quality program to promptly detect and correct assignable conditions adverse to quality. The Contractor shall make available the quality system procedures, planning, and other documentation and data that comprise the quality system to 76th Propulsion Maintenance Group Production Management Specialist (OC-ALC/76 PMXG/OBD) for review upon request.

1.3.3 Deficiency Investigation Report

The Contractor shall investigate suspect defective items IAW TO 2-1-111 & PWA 46 and submit findings to include root causes and corrective actions as appropriate. The Contractor shall submit the report within 60 days after receipt of the Product Quality Deficiency Report (PQDR) Exhibit. (CDRL A001 – DI-ALSS-81534)

1.3.4 Measuring and Test Equipment (M&TE)

The Contractor shall use only National Institute of Standards and Testing (NIST) traceable gages. The Contractor shall ensure the M&TE and measurement standards are labeled to indicate calibration status. The Contractor shall ensure the label identifies, as a minimum, specific date calibrated (day, month, and year, Julian date or equivalent) and the specific calibration due date. Contractor shall affix tamper resistant seals to operator accessible control or adjustments on M&TE and measurement stands that, if moved, shall affect the calibration.

1.3.5 Handling of Government Property

The Contractor shall handle all Government property received at the Contractor’s repair facility in accordance with the applicable technical data, and shall maintain constant care over these items while in their possession.

1.3.6 Material Review Board (MRB)

The Contractor is authorized to establish and convene an MRB to evaluate and non-conforming material and/or parts. Board members shall consist of representatives from the contractor’s quality, production control, and engineering (industrial product support or design). The Contractor shall prepare a report within 30 days after entering MRB pool detailing the non-conformance to include PN, NSN, and SN. The PMS shall provide disposition instructions to the Contractor through the PCO. (CDRL A002 – DI-

ILSS-80386)

1.4 Technical Requirements

The Contractor shall apply the PWA-46, LW-IN40- Tungsten carbide Coating on the F100-PW-220 & 220E 1st thru 3rd Stage Compressor Rotor Blades in IAW the USAF technical orders identified in Section 3.1.2 and deliver coated parts IAW the basic contract.

1.4.1 Receiving

The Contractor shall provide an “as received” inspection of assets to determine the serviceability or reparable condition of the F-108/CFM 56-2A/2B engine component using 2J-F108-13-72-21-01-200-001. The Contractor shall prepare and forward a Report of Discrepancy (ROD), SF 364, to the shipping activity for corrective action to prevent reoccurrence. The Contractor shall submit discrepancy reports IAW Appendix B.

1.4.2 Process Repairs

The Contractor shall be responsible for performing and certifying all repairs required in this PWS IAW the qualification procedures. The prime Contractor shall validate but shall not certify sub-vendors; the Government will certify any and all sub vendors

1.4.3 OC-ALC/76 PMXG reserves the right to audit any process excluding proprietary processes at any time in the duration of this contract.

1.4.4 Inspection

RESERVED

1.4.5 Plasma Spray Requirements

The Contractor shall apply PWA 46 LW-IN40-Tungsten Carbide, in accordance with T.O

2J-F100-13-6, WP 417 00, 2J-F100-53-6, WP 415 00, 2J-F100-13-2, WP 004 00 & T.O

2-1-111. The Contractor shall ensure sufficient plasma spray coating is applied to meet T.O. coating thickness requirements and surface finish.

1.4.5.1 Plasma Spray Testing for Production Lots:

The Contractor shall perform metallurgical examination and tensile bond strength testing as per Standard Maintenance Procedures T.O. 2-1-11 and PWA 46 per 12 hour shift or at any change in set up. The Contractor shall provide the reports in accordance with Section 1.4.9.

1.4.5.2 The Contractor shall perform the following laboratory test IAW PWA-46.

• Metallurgical examination of one flat panel. Microstructure examination shall include porosity, oxides content, media entrapment, unmelt, voids, and thickness requirement

• Hardness Coupon

• Tensile bond strength testing shall be conducted to determine the tensile strength per coating.

• Microstructure, hardness, and tensile bond bars geometry shall meet standard testing procedures for PWA 46. The bars shall be sprayed to represent the same geometry as the production hardware .

1.4.6 Plasma Spray Production Acceptance Criteria:

The Contractor shall use PWA 46 for acceptance/ reject criteria of the plasma spray coating. The contractor shall inspect the coated blades IAW PWA 46 and LW-IN40.

The Contractor shall ensure the coating adheres to the base metal and shall be a uniform, continuous surface free of spalling, chipping, flaking, cracking, or other imperfections detrimental to the usage of the coating. Any indication of oil seepage from the coating will be cause for rejection. The Contractor shall ensure coated fan blades meet the final dimensional requirements of T.O. 2J-F100-13-6, WP 417 00 & T.O. 2J-F100-53-6, WP 415 00.The Contractor shall remove non-conforming coating per the applicable tech data and reprocess the part through the repair.

1.4.7 Tooling:

Tooling and/or alternate tooling to that specified by the OEM and/or with applicable US Government Technical Orders or FAA Approved Engine Manual may be developed and applied as required to produce the specified completed characteristics. Final results required by the PWS and/or contract will be met.

1.4.8 Coating Material Source Control:

The Contractor shall purchase Plasma spray materials from Government approved sources listed below:

Material Vendor Cage Code Address

LW-IN40

Tungsten Carbide Praxair North Haven, CT

Indianapolis, IN Charlotte, NC

1.4.9 Repair Documents

A “Certificate of Conformance” shall be provided by the contractor inside the shipping container for each part shipped. The Contractor shall ensure the “CoC” provides details on how the Contractor controls the quality of the part, and certify that the part was handled and repaired according to all applicable technical data. The contractor shall provide the following CoC as detailed below with each part shipped.

• Inspection and All lab results as listed in 1.4.7

• Material certificates of conformance (COC) for all D-GunTM coatings IAW 1.4.5

The Contractor shall submit a sample copy of the CoC to 76 PMXG/OBD for Government approval prior to production. The Contractor shall prepare a report within 30 days after entering MRB pool detailing the non-conformance to include PN, NSN, and SN. The PCO will provide disposition instructions to the Contractor. The Contractor shall investigate suspect defective items IAW TO 00-35D-54 and submit findings to include root causes and corrective actions as appropriate. The Contractor shall submit the report within 60 days after receipt of the PQDR Exhibit. (CDRL A003 -

DI-MISC-81356)

1.4.10 Records and Reports

The Contractor shall keep on file all records and reports outlined in this PWS for five years. The Government’s Technical Representative (OC-ALC/76 PMXG/OBD) reserves the right to request and view any records at any time.

1.4.11 Delivery

The Contractor shall meet or exceed the delivery schedule. The PCO may at any time during performance under this contract/order, by written authorization through the ACO, authorize fast transportation for the total contract/order quantity or any portion thereof.

Transportation for end items on this contract are authorized to ship via air/land utilizing a Government approved carrier. Once PCO authorization for Fast Transportation has been received, the Contractor shall ship end items by one of the following methods:

(1) Domestic Shipments – Ship overnight/Next Day Service

(2) International Shipments – Ship via a carrier providing door-to-door priority service, to include delivery within two to three days, and customs clearance, to final destination.

1.4.12 Transportation Information

The Contractor shall provide the transportation information IAW Appendix B.

1.5 Production Problems

1.5.1 The Contractor shall report any potential production slippage or work stoppages to the Administrative Contracting Officer (ACO), PCO, and the PMS Production Management Specialist (PMS) at the managing ALC. If problems are not resolved, the Contractor shall report them to the ACO.

1.5.2 Process Reassessment:

During the duration of the contract, all production planning for the plasma spray process is frozen after the initial setup. If process changes or improvements are required thereafter, the contractor shall obtain approval from OC-ALC/76 PMXG prior to completing any further production.

1.5.3. Production Report (CDRL) – DI-ALSS-80728A

The Contractor shall submit the Depot Maintenance Production Report in accordance with referenced CDRL. (CDRL A004)

1.5.4 Continuation of Essential DoD Contractor Services During Crisis This requirement has been determined not to be Mission essential and does not require continued support during a crisis as defined in DoDI 3020.37, E2.1.1 and E2.1.3.

1.5.5 Green/Affirmative Procurement Determination

Green/Affirmative Procurement has been determined not to be applicable to this Performance Work Statement.

1.6 Contractor Manpower Reporting

The Contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the United States Air Force via a secure data collection site. The contractor is required to completely fill in all required data fields at http://www.ecmra.mil.

Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October* of each calendar year. Contractors may direct questions to the CMRA help desk.”

*Reporting Period: Contractors are required to input data by 31 October of each year.

Uses and Safeguarding of Information: Information from the secure web site is considered to be proprietary in nature when the contract number and contractor identity are associated with the direct labor hours and direct labor dollars. At no time will any data be released to the public with the contractor name and contract number associated with the data.

User Manuals: Data for Air Force service requirements must be input at the Air Force CMRA link. However, user manuals for government personnel and contractors are available at the Army CMRA link at http://www.ecmra.mil.

2 SECTION II – SERVICES SUMMARY.

2.1 Performance Requirements

The Contractor service requirements are summarized into performance requirements that relate directly to mission critical items. The performance requirement threshold briefly describes the minimum acceptable levels of service for each requirement. These requirements are critical to the mission success. The Government will use the surveillance methods contained in the Quality Assurance Surveillance Plan (QASP) to evaluate the Contractor’s performance for the requirements listed below. In the event the requirement is not met, and is correctable, the Contractor shall immediately take corrective action in accordance with the performance threshold(s).

2.2 Service Summary (SS) Requirements

The Contractor shall ensure the performance objectives and performance requirement thresholds identified in Table 2-1 (below) are achieved.

2.3 Surveillance

Table 2-1

Performance Objective Reference Paragraph Performance Threshold

SS-1 The Contractor shall investigate suspect defective items IAW TO 2-1-111 and submit finds to include root causes and corrective actions as appropriate. The Contractor shall prepare a report within 30 days after entering MRB pool detailing the non-conformance include PN, NSN, and Serial Number (SN). A “Certificate of Conformance” shall be provided by the contractor inside the shipping container for each part shipped. The contractor shall submit the Depot Maintenance Production Report in accordance with CDRL.

1.3.3 1.3.6 1.4.6 1.5.3

Required 10 working days after entering MRB pool. At least 98% of information must be accurate.

SS-2 The Contractor shall meet or exceed the delivery schedule.

1.4.11 Assets shall be

returned within 21 days calendar days from receipt.

SS-3 The Contractor shall develop and maintain a quality management system in compliance with ISO/ANSI/ASQ Q9001:2001, Quality systems – Model for quality assurance in production, installation and servicing, as a minimum. The Contractor’s quality program shall be designed to promptly detect and correct assignable conditions adverse to quality.

The contractor shall apply the PWA-46, LW-IN40- Tungsten carbide Coating on the F100- PW-220 & 220E 1st thru 3rd Stage Compressor Rotor Blades in IAW the USAF technical orders identified in Section 1.2.2 and deliver coated parts IAW the basic contract.

1.3.2 1.4

No more than 2 defects per delivery

SS-4

The Contractor shall provide the transportation information IAW Appendix B.

1.4.12 100% Compliance

3 SECTION III – Government Furnished Property and Services.

See Appendix B.

3 SECTION III – Government Furnished Property and Services.