AppendixAPerformanceWorkStatement.pdf

Performance Work Statement

(PWS)

For TF33 Compressor Inlet Case Inlet Guide

Vanes (IGV’S) Rubber Burnout Heat-Treating Service

PREPARATION DATE: 11 Jan 2018

PREPARING ORGANIZATION: OC-ALC/76 PMXG TINKER AFB OK 73145

1 SECTION 1 – SCOPE

1.1 OC-ALC/76 PMXG requires rubber burnout heat-treating services to support mission requirements of the TF33 Compressor Inlet Case Inlet Guide Vanes (IGV’S).

The Contractor shall be responsible for the quality control, and processing of components requiring heat treatments.

Part Numbers (PN):

NSN: 2840-01-167-9584RV (MST) PN: 800225

NSN: 2840-00-442-7111RV (SUB) PN: 633684

P103 – Compressor Inlet Case

NSN: 2840-00-442-7112RV (MST) PN: 633682

NSN: 2840-00-015-8050RV (SUB) PN: 502337

NSN: 2840-00-962-3308RV (SUB) PN: 479093

NSN: 2840-00-020-3484RV (SUB) PN: 462845

NSN: 2840-00-977-6310RV (SUB) PN: 436119

P5/9/102/103 All - Compressor Inlet Case

1.1.1 The Contractor shall furnish all required tooling, labor, material, parts, facilities, test equipment and any incidentals necessary to provide rubber burnout heat-treating for the TF33 Compressor Inlet Case Inlet Guide Vanes. All services shall be provided in accordance with (IAW) this Performance Work Statement (PWS).

1.1.2 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 76th Propulsion Maintenance

Group Production Management Specialist (OC-ALC/76 PMXG/MXDEO) 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 Industry Documents.

1.2.3 USAF Technical Orders/ Forms.

Publication Number Title Basic Date Latest Chg

Number Latest Chg Date

2J-TF33-

53-7 WP003 00 para. 4

Technical Manual Maint Instruction Depot Repair

15 Sep 2012 9 15 Mar 2017

T.O. 2-1-111 SPOP 209

Method B or C.

Standard Maint Procedures P&W Aircraft Engines

15 Feb 1990 66 15 Sep 2016

2J-TF33-53-1 SWP 017

Heat Treatment:

Stress-Relief Cycles

15 Sep 2012 5 15 Mar 2017

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 be required to comply with such laws when they come into effect. If there is an increase or decrease in cost because of the change, the Contractor shall inform the Contracting Officer (CO) of the change and the CO will determine if an equitable adjustment is required.

1.3.2 Quality System Requirements:

The Contractor shall develop and maintain a quality management system in compliance with ISO/ANSI/ASQ Q9001: 2015 or latest version, or equivalent 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 quality system procedures, planning, and other

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

2015 N/A N/A documentation and data that comprise the quality system shall be made available to 76th Propulsion Maintenance Group Production Management Specialist (PMS) (OC- ALC/76 PMXG/MXDEO) for review upon request.

1.3.2.1 Deficiency Investigation Report:

When the Contractor receives a deficiency report on an item required under the terms of the contract, the Contractor shall comply with the ACO’s directions. 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 report shall be submitted within 60 days after receipt of the PQDR Exhibit. (CDRL A001 – DI-ALSS-81534 - Deficiency Investigation Report)

1.3.3 Measuring and Test Equipment (M&TE):

M&TE and measurement standards shall be labeled to indicate calibration status. The label shall identify, as a minimum, specific date calibrated (day, month, and year, Julian date or equivalent) and the specific calibration due date. Tamper resistant seals shall be affixed to operator accessible control or adjustments on M&TE and measurement stands that, if moved, shall affect the calibration. Calibration procedures must meet one of the following: ISO 10012-1, ANSI/NCSL Z540-1, or MIL-STD-45662. M&TE used must discriminate to within 25 percent of the total tolerance for the feature being inspected (ie. gage accuracy to part tolerance ratio of 4-to-1).

1.3.4 Handling of Government Property:

The Contractor shall handle all government property received at the overhaul site in accordance with the applicable technical data, and shall maintain constant care over these items while in their possession. The contractor shall protect all parts from damage as they are processed through the shop.

1.3.5 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) and Government Quality Assurance Representative (QAR). The Contractor shall prepare a report within 30 days after entering MRB pool detailing the non-conformance to include Part Number (PN), National Stock Number (NSN), and Serial Number (SN). The Contractor shall provide the report to the PMS and PCO. The PCO shall provide disposition instructions to the Contractor. (CDRL A002 – DI-ILSS-80386 - Material Review Board data)

1.3.6 Rubber Decomposition Products:

Rubber decomposition products must be treated and disposed of in accordance with any local, state, or federal laws that apply at the location of the vendors’ facility.

1.3.7 Rubber Specifications:

The rubber material found in the IGV struts meets PWA 404, PWA 405, or PWA 407 material specifications, also RTV 630 and RTV 668 are GE material specifications that meet these PWA specifications. All Material Safety Data Sheets (MSDS) that are available are provided as an attachment. Each manufacturer develops a MSDS for their product; there may be several MSDS for the same type of rubber.

1.3.8 Effluents:

During burnout hazardous gases are emitted from the rubber as part of the decomposition process. A thermal incinerator is required to fully burn the gases prior to emission to the atmosphere. Contractor must have furnaces equipped with operational Thermal Incinerators due to the effluents given off when performing the burnout processes.

1.3.9 Ash:

The ash residue remaining in the furnace and in the part from the rubber burnout is primarily silicon. However, we have detected lead and cadmium in the ash and in the RTV installed in the case struts. The screen results for lead and cadmium from our furnace samples and from some representative IGV parts are as follows: X-Ray: no Pb or Cd detected (<detection limit). ICP: Ash: Pb none detected (<10ppm), Cd 21 ppm (ug/gram). RTV: Pb 35 ppm, Cd 73 ppm.

1.3.10 Contractor must have Engineering Controls in place for handling ash to prevent operator exposure to cadmium and lead.

1.3.11 Contractor shall maintain furnaces that are certified per AMS 2750E. Uniformity is expected for all temperatures at +/- 25 degrees F. Uniformity tests shall be performed for temperatures <1500 degrees F. Uniformity tests shall be performed at the set point temperature of 1050 degrees F. A variance of +15/-15 degrees F from the set point temperature is allowed.

1.3.12 Contractor shall use only National Institute of Standards and Testing (NIST) traceable controllers and thermocouples (Type K; individual or from a certified roll). The furnaces shall be equipped with separate control and over-temperature thermocouples, certified annually or at more frequent intervals if necessary. Controllers shall be calibrated annually, at a minimum. Contractor shall use a calibrated chart recorder to log the furnace and workload thermocouple temperatures.

1.4 SECTION V – PROCEDURE.

1.4.1 The Contractor shall perform a receiving visual inspection upon receipt of part for any shipping and or packaging damage. The Contractor shall prepare a report of Discrepancy (ROD), SF 364, and forward it to the shipping activity for corrective action to prevent reoccurrence. The Contractor shall prepare and submit Discrepancy reports IAW PWS Section 1.6.3.

1.4.2 Contractor shall accomplish pre and post burnout cleaning by hand scrub and then power wash on subject parts. This is per T.O. 2-1-111 SPOP 209 Method B or C.

1.4.3 The workload thermocouples should be allowed to stabilize before soak times are started.

1.4.4 If necessary, contractor shall use only dustless white chalk to highlight/mark the part number and serial number of each component.

1.4.5 IGV’S (approx. 60” dia.) may be stacked no more than four high in a furnace provided each layer is separated using a steel spacer (contractor provided).

1.4.6 Contractor shall provide and use flat plate (flat within 0.010” over length of plate) for base/hearth plate for stacking parts. Flatness shall be verified and when necessary corrected at least once every five burnout cycles.

1.4.7 Contractor shall attach a minimum of four workload thermocouples per part.

Thermocouples shall be placed as follows:

1. Outer shroud closest to heat source.

2. Outer shroud farthest from heat source.

3. Inner shroud

4. Vane Readings of all four thermocouples shall be included in the chart record.

1.4.8 Contractor shall return with the shipment the original recorder charts for each batch of component parts processed. Contractor shall mark the chart with the contractor’s furnace number, cycle type, component part numbers, serial numbers, national stock numbers, time started and time finished for each soak logged and initialed, interval operator checks initialized throughout the cycle, chart recording speed, and operator’s printed name and signature. Contractor shall log all temperatures throughout the cycle. (CDRL A003 – DI-MISC-80508B)

1.4.9 The heating and cooling rate must be sufficiently slow to avoid unacceptable stress and distortion. Temperature variation within part shall not exceed 50 degrees F at any time during burnout cycle. Temperature shall be recorded to below 200 degrees F during cooling.

1.4.10 The burnout heat treat cycle shall be accomplished as authorized in T.O. 2J- TF33-53-7 WP003 00 Para. 4.

1.4.11 After the burnout cycle the contractor shall “probe” each vane with a long wire or pipe cleaner to break up residual rubber inside the vanes. This will be followed with the vacuuming of the residue.

1.4.12 Contractor shall power wash each IGV with high-pressure water to remove burned rubber residue per T.O. 2-1-111 SPOP 209 method B or C.

1.4.13 Contractor shall observe trend and request time extension at burnout temperature accordingly from the AFLCMC/LPSEA Cognizant Engineering Authority.

1.4.14 If 90% of the residue (RTV) is unable to be satisfactorily removed after one recycle per this PWS, the contractor shall convene a Material Review Board and comply with para. 1.3.5 of this PWS.

1.4.15 Records and Reports:

All records and reports outlined in this PWS shall be prepared for each part and kept on file by the contractor for five years. The 76th Propulsion Maintenance Group Production Management Specialist (OC-ALC/76 PMXG/MXDEO) reserves the right to request and view any records at any time.

1.4.16 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 – No later than four business days or the earliest available delivery date thereafter.

1.4.17 Transportation Information:

The Contractor shall provide the transportation information IAW PWS Section 1.6.

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 Production Management Specialist at the managing Air Logistic Center. If problems are not resolved, the Contractor shall report them to the ACO. The ACO will forward all problems to the PCO and the PMS.

1.5.2. Production Report:

The Contractor shall submit the Depot Maintenance Production Report in accordance with referenced CDRL. (CDRL A004 - DI-PSSS-81995)

1.5.3 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.

1.5.4 Green/Affirmative Procurement Determination:

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

1.6 SHIPPING AND TRANSPORTATION.

1.6.1 The Government will pack and ship the TF33 Compressor Inlet Case IGV’S to the Contractor for repair at the Government’s expense, Freight On Board (FOB) Destination.

Note: The TF33 Compressor Inlet Case IGV’S become Government Furnished Property (GFP) when shipped off-base. See PWS Section 3 regarding GFP.

1.6.2 The Contractor shall transmit a copy of the Bill Of Lading and tracking number by e-mail or phone to the following Government POC within 12 work hours as deliverables are shipped:

Jimmy Horton, 76 PMXG/MXDEO

PH: 405-736-5556

Email: jimmy.horton@us.af.mil

The Contractor shall ship or transport applicable assets as appropriate in order to have assets available to support the customer’s operational requirements. The Contractor shall meet the contracted delivery schedule. Shipments under this contract shall be by fastest traceable means FOB Origin.

Ship to: DODAAC: FY2339

548th PMXS/MXPEX Attn: Ronny Young or Jimmy Horton PH: 405-734-8983 or 405-736-5556 Bldg 3001 Staff Drive North Door 6 3221 Entrance Road A Tinker AFB, OK 73145-3303

1.6.3 Shipment Discrepancy:

Government Property received by the Contractor and recognized as misdirected, will be rerouted to the correct location if known by the Contractor. If the correct location cannot be identified, contact the OC-ALC/76 PMXG PMS.

A Supply Discrepancy Report, SF 364, will be prepared and forwarded to the shipping activity for corrective action to prevent reoccurrence. Manual Discrepancy reports shall be submitted by e-mailing the following address: dlacontactcenter@dla.mil. Their commercial number is (877) 352-2255 or DSN: 661-7766, FAX number (269)-961-7791, DSN: 661-7791.

1.6.4 Terms Explained:

1.6.4.1 Julian Date: A method used by the government to track days according to a system usually covering one year and referring the days of each week to the days of the month. (Example: Julian Date 2098. Number mailto:dlacontactcenter@dla.mil

2 refers to the year 2002, and 098 refers to the ninety-eighth day of the year, the eighth day of April (example 8 April 2002)

1.6.4.2 Material Support Division (MSD) Items:

Items that have an ERRC code of C (XD1) or T (XD2). These items are referred to as line replacement units (LRU) and shop replacement units (SRU) respectively.

1.7. Health and Safety off Government Installations: While performing work under this contract the contractor shall comply with all applicable federal, state and local regulations regarding occupational safety and health. During the execution of the contract, the Contractor shall notify the CO within one (1) business day of any damage to Government property in which the dollar value exceeds $500,000.00 and within two

(2) work days, for any damage to Government property less than $500,000.00.

Mishap notifications shall contain, as a minimum, the following information:

• contract name, contract number, name and title of the persons reporting the accident/incident

• date, time, and exact location of accident/incident

• a brief narrative of the accident/incident (Events leading to accident/incident)

• cause of accident/incident, if known

• estimated cost of the accident/incident (material and labor to repair/replace)

• nomenclature of the equipment and the names of the personnel involved in accident or incident

• corrective actions taken or proposed

• other pertinent information

If requested by the designated CO, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office. Contractors will not dispose of contract data related to a mishap until notified to do so by the CO.

1.8 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:

The assigned 76th Propulsion Maintenance Group Production Management Specialist (OC-ALC/76 PMXG/MXDEO) will use the surveillance methods contained in the QASP to evaluate the Contractor’s performance to determine if it meets the performance thresholds listed in this PWS.

Table2-1

Performance Objective Reference Paragraph

Performance Threshold

SS-1 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 report shall be submitted within 60 days after receipt of the PQDR Exhibit. The contractor is authorized to establish and

1.3.2.1 1.3.5 1.4.8 1.5.2

Required 100% timely delivery of each data report IAW CDRLs. At least 98% of information must be accurate.

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) and Government QAR. The Contractor shall prepare a report within 30 days after entering MRB pool detailing the non-conformance to include PN, NSN, and SN.

The Contractor shall provide the report to the PMS and PCO. The PCO shall provide disposition instructions to the Contractor. Contractor shall return with the shipment the original recorder charts for each batch of component parts processed. Contractor shall mark the chart with the Contractor’s furnace number, cycle type, component part numbers, serial numbers, national stock numbers, time started and time finished for each soak logged and initialed, interval operator checks initialized throughout the cycle, chart recording speed, and operator’s printed name and signature. Contractor shall log all temperatures throughout the cycle. The Contractor shall submit the Depot Maintenance Production Report in accordance with referenced

CDRL .

SS-2 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

1.4.16 Assets shall be returned

within 30 days calendar days from receipt.

on this contract are authorized to ship via air/land utilizing a Government approved carrier.

SS-3 The Contractor shall develop and maintain a quality management system in compliance with

ISO/ANSI/ASQ Q9001: 2015,

or equivalent 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 quality system procedures, planning, and other documentation and data that comprise the quality system shall be made available to OC-ALC/76 PMXG for review upon request.

1.3.2 100% Compliance

SS-4 Contractor shall transmit a copy of the Bill Of Lading and tracking number by e-mail or phone to the following Government POC within 12 work hours as deliverables are shipped.

1.6.2 100% Compliance

3 SECTION III – Government Furnished Property and Services

3.1 GENERAL:

Government Furnished Property (GFP) is applicable to the performance of this contract. The TF33 Compressor Inlet Case IGV’S require repair off-base as described in PWS Section 1 and listed in the GFP Attachment #3.

3.2 SHIPPING AND TRANSPORTATION:

In accordance with PWS Section 1.6.

3.3 LOSS OF GOVERNMENT PROPERTY:

In accordance with the Government Property contract clauses.

3.4 DISPOSITION OF GFP:

The PCO will furnish to the Contractor final disposition instructions for all GFP.

Plant Clearance Automated Reutilization Screening System (PCARSS) shall not be required for disposal of GFP.

3.4.1 Condemned Government Property:

The Contractor shall request from the PCO, disposition instructions for all items, such as critical items, MSD and save list items that are condemned during the performance of this contract. All recommended condemnations shall be tagged and returned to OC-ALC Tinker AFB using a DD Form 1149.

3.4.2 Processing of GFP Rejects:

Action to be taken in disposing of GFP that exceed present remanufacture and inspections limits shall be condemned at the Contractor’s facility and data provided to the OC-ALC/76 PMXG PMS with the monthly on monthly production form AF Form 413.

3.4.3 Contract Excess:

The Contractor shall ensure that all excess repairable end items being returned to the Air Force have the note “Contract Excess” entered into the shipping documents to preclude OC-ALC recording such excess as additional repairable generations. The Contractor shall ensure that excess repairable end items are returned to OC-ALC unless another address is specified.

The Contractor shall use a DD Form 1149 in returning excess, Government repairable end items. The Contractor shall transmit a copy of the DD Form 1149 to the OC- ALC/76 PMXG PMS within 12 work hours after shipment.

3.5 GOVERNMENT FURNISHED SERVICES:

Government Furnished Services (GFS) are not applicable to this contract.

3 SECTION III – Government Furnished Property and Services