T56_3_5_Pre-Proposal_Vendor_Telecom_3_5_Overview_and_SAR_Overview_4_Dec_15.pdf

AFLCMC… Providing the Warfighter’s Edge

T56-A-15A Series 3.5 Modification and

Source Approval Request (SAR) Package Submittal

Overview Pre-Proposal Vendor Telecom

4 Dec 15

Dana Grilley Richard Whitehurst

Air Force Life Cycle Management Center

This briefing is For Official Use Only (FOUO)

DISCLOSURE NOTICE – This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United

States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether parented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without the written approval of the originating United States agency.

Disclosure Notice

Outline

• T56-A-15A Series 3.5 Modification Overview

• SAR Submittal Overview

T56 3.5

PROGRAM OVERVIEW

T56-A-15A Series 3.5 Overview

• Requirement:

⎯ Provide 50 each serviceable 3.5 Compressor and Turbine Modules for 40 installed engines, 8 engine spares and 2 Compressor and Turbine Module spares

• Supports 10 LC-130 Aircraft (4 engines per each aircraft) across FY16-18 ⎯ 6 Air National Guard (ANG) aircraft – 24 engines

• 1st 8 engines will initially support FY16 Force Development Evaluation (FDE) study (2 aircraft)

⎯ 4 National Science Foundation (NSF) aircraft – 16 engines

• Strategy:

⎯ Buy sole source Rolls-Royce mod hardware kits and tools

⎯ Install mod hardware via depot-level competed Module Overhaul/Repair Services

Contract

⎯ Utilize T56-A-15 Series 3.0 reparable Compressor and Turbine modules for depot build

⎯ ANG field units order serviceable 3.5 modules for engine build-up

⎯ ANG field units install serviceable 3.5 engines into LC-130 aircraft

Vendor Support

• MAJCOM: ANG

• OEM: Rolls-Royce

• Efficiency & Operational Mod Benefits:

⎯ Reduced fuel consumption by 7.9% ⎯ Increased Engine Time On Wing by 23% ⎯ Higher fuel quantities offloaded per sortie for increased range and payload at cruise ⎯ Improved Aircraft Availability to meet increasing sortie generation demands

• LC-130H Interface:

⎯ No aircraft installation/interface changes ⎯ No flight deck control changes

LC-130H MISSION

• Antarctica Operation Deep Freeze (ODF)

⎯ Move cargo from Christchurch, New Zealand to McMurdo, Antarctica

⎯ Move cargo from McMurdo to satellite sites

⎯ Move fuel from McMurdo to South Pole Station

• Support Greenland scientific missions ⎯ Personnel and supply transportation

COMPETED DEPOT LEVEL CONTRACT

• Approved SAR required for award eligibility

• Award based on Lowest Priced Offer who is deemed technically acceptable with acceptable past performance

• FAR 15 Firm-Fixed Price 3-Year ID/IQ Contract ⎯ 1 year basic ⎯ Two 1-year options

KEY INFO

T56 3.5 Overview (cont)

New Compressor Inlet Housing

Turbine Aero Redesign

Improved Blades & Vanes

Improved Compressor Blade Surface Finish

Updated Compressor Wheels

Knife-edge Seals Uncooled Single Crystal Stage 1 Turbine Blade

Reduced Number of Vanes per Stage

Flowpath Improvements

Work-per-Stage Optimization

Improved Tip Clearances

MOD HARDWARE

Technology Readiness

Critical Technology Element TRL

None 9

Technology Readiness Levels

(TRL)

9. Actual system “flight proven” through successful mission operations

8. Actual system completed & “flight qualified” through test & demo

7. System prototype demonstration in a operational environment

6. System/subsystem model or prototype demonstration in a relevant environment

5. Component and/or breadboard validation in relevant environment

4. Component and/or breadboard validation in laboratory environment

3. Analytical & experimental critical function and/or characteristic proof-of-concept

2. Technology concept and/or application formulated

1. Basic principles observed & reported

• No new technologies involved

• Modification applies existing technologies from other proven systems ⎯ Improved compressor knife rotating seals with aluminum polyester abradable – from AE series and T56 Series IV engines

⎯ XPT-268 abradable compressor case coating

– from AE2100/AE3007 and 501K industrial engines

⎯ REM superfinished compressor blades – from 501K industrial engines

⎯ Single crystal Stg 1 turbine blade – from AE series engines

Systems Engineering

• Operational Safety, Suitability and Effectiveness (OSS&E)

– Approved T56-A-15 OSS&E Assurance Plan documented as Appendix to T56 Engine Life

Management Plan

– Cognizant Engineering Authority (CEA) – AFLCMC/LPS Engineering

• Interacts with C-130 SPO Engineering, ANG (Lead Command Propulsion Functional), and OEM Rolls- Royce Corporation

– USAF has no fielded Series 3.5 at this time

• Configuration Management (CM)

– Configuration change from T56-A-15 Series 3.0 to T56-A-15A Series 3.5

– T56-A-15A functional configuration baseline established by new engine Model Specification No.

– Physical configuration baseline is documented in T.O. 2J-T56-54 Parts Breakdown

– Design changes managed by LPS configuration control board in accordance with LPS Operating

Instruction 21-004

– New Comprehensive Engine Management System (CEMs) TMSM and tracked Configuration Item

Identifiers (CIIs) to be established for 3.5 items

• Deficiency Reporting (DR) Process

– IAW T.O 00-35D-54 reporting requirements and timelines, and PWS

• Corrosion Prevention and Control Plan (CPCP)

– No corrosion issues / not applicable: following standard C-130 T56 3.0 technical data

Data Management & Information Management Strategy

• Govt owns T56-A-15 technical manuals and red-line technical manuals for 3.5

– Vendors will use preliminary TCTO data for installation contract

• Govt CEA will perform TCTO val-ver during first module overhaul / kit installation

– Vendors will support Govt CEA val-ver of red-line technical manuals for future sustainment repair/overhaul

Market Research / Competition Approach

• Vendor Notifications on FedBizOps:

– Request for Information (RFI) posted Nov 14

– Sources Sought Synopsis (SSS) posted Aug 15

– Draft Request for Proposal (RFP) posted Sep 15

– Formal RFP (solicitation) posted 6 Nov 15

– Responses to Vendor Questions posted Sep-Dec 15

– Pre-Proposal Telecom held 4 Dec 15

– Proposals Due 22 Dec 15 3:00 p.m. CST

• NAICS Code = 336412 engine overhaul

– SB size standard = 1,000 employees or less

• PSC Code = J028 maintenance / repair of engines and turbines

• Contract Award targeted for 31 Mar 16

• CLIN Structure

– 0001: Compressor Module Overhaul / Mod Hardware

Installation, FFP

– 0002: Turbine Module Overhaul / Mod Hardware

Installation, FFP

– 0003: Over & Above (O&A), FFP Labor Wrap Rate

– 0004: 3.5 Compressor Module Sustainment Repair, FFP

– 0005: 3.5 Turbine Module Sustainment Repair, FFP

– 0006: 3.5 Module Sustainment Tech Data Val-Ver, FFP

– 0007: Data (CDRLs and Reporting), Not Separately

Priced (NSP)

– 0008: Travel, Cost Reimbursable

Module Overhaul/Repair Service Contract CLINs

T56-A-15A (3.5)

SOURCE APPROVAL REQUEST

(SAR)

SUBMITTAL OVERVIEW

Background Qualification Requirements

• Qualification Requirement (QR): The minimum criteria set forth by the Engineering Support Activity to become an approved (qualified) source to either manufacture or repair/overhaul an item

• Source Approval Request (SAR): A technical data package submitted by a contractor which includes all data/documentation/information required for a competent manufacturer/repair source to be qualified to manufacture or repair an item

• Source Development (SD): Function assigned within the Small Business (SB) Office at Air Logistics Centers to increase competition. The Source Development Specialist manages the SD function of the SB program

FAR 9.2 established the regulatory requirement for establishing a Qualification Requirement

T56 Repair Qualification Requirements

• All contractors performing T56 upgrade, overhaul, and repair services must be qualified prior to contract award by the USAF engineering support activity (AFLCMC/LPSE)

– Pre-Contract Repair Qualification Requirements are established and posted to FedBizOps at:

• https://www.fbo.gov/spg/USAF/AFMC/OCALCCC/T56RepairQualificationRequirements/listing

.html

• Link is also provided on synopsis for FA8121-16-RR_T56_35

• Current Qualification Requirement is RQR-1 T56 Revision 1, dated 2 Feb 12

– For the current requirement, a source approval request is only required to be submitted for power section assembly, P/N 6842602

Module and Reparable Item Approvals

• Approval for repair of the top level assembly will approve a source for repair of all indentured reparable subassemblies and components

– Source will be added to USAF approved repair source list for all power section reparables based on a single SAR package

– Includes turbine module and compressor module

SAR Submittals

• RQR-1 T56 provides for a two part qualification process

– Part I: Documentation of Experience and Capability

– Part II: Substantiation of Repair Procedures by Source Demonstration

• Source Demo is not required for offerors that have previously overhauled the “same item” and that are Rolls Royce FMC/AMC/AMOF

• Part I Guidance The following guidance is to reduce rework and flow time based on past SAR reviews. SARs must comply with all requirements of RQR-1 T56

• Sources must provide proof of capability to overhaul the same item (Cat 1 offeror) or similar item (Cat 2 offeror)

– Delivery of production quantities of any T56 SIII power section overhauls will be considered the same as the “approval part”

– Multiple P.O.s and shipping documents with customer acceptance may be required 16

• Part I Guidance (continued)

– Copy of OEM certifications must be provided; i.e. FMC/AMC/AMOF agreements

– Verification of compliance to AS 9100/ISO 9001 or equivalent by an independent auditing organization must be furnished

– Identification of repair subvendors used in past efforts is required

– Repair subvendors for components/subassemblies/significant processes to be used in planned effort is required, with evidence of their capability (i.e. NADCAP or OEM certs, past experience, vendor quality rating and process)

• SARs shall be submitted to Tinker AFB Small Business:

• AFSC/SB

3001 Staff Drive, Ste 1AG85A Tinker AFB, OK 73145-3009

• For questions and assistance, contact:

– Mr. Joe Roop (until 30 Dec 15) and Ms. Laurel (Chip) Chambers at

405-739-7243

– AFSC/SB Web site: (http://www.tinker.af.mil/sbo.asp) 18