HC-27J Integral Fuel Tank Repair and Flight Deck Window Strip.pdf

STATEMENT OF WORK (SOW)

HC-27J Integral Fuel Tank Repair & Flight Deck Window Frame Stripping

1. BACKGROUND

Through the National Defense Authorization Act of 2014, the United States Coast Guard (USCG) has acquired fourteen HC-27J aircraft from the United States Air Force. The HC-27J is a medium size military transport aircraft that is manufactured by Leonardo Company (Italy). Initially, CG-9 established the HC-27J Asset Project Office (APO) Elizabeth City to make these aircraft ready for USCG use.

Currently, the Aviation Logistics Center (ALC) is responsible for the program depot maintenance (PDM), supply support, technical/engineering support and contracting related to the HC-27J. The aircraft is specifically equipped to perform all USCG missions that include: search and rescue, maritime safety, security, and logistics, as well as national defense and protection of natural resources.

2. SCOPE

The scope of this SOW establishes a one-time purchase for repair services of the HC-27J aircraft integral fuel tanks and flight deck window frames. The work will be conducted in three phases where the contractor will complete Phase 1, the government will complete Phase 2, and the contractor will complete Phase 3.

Phase 1 - The contractor will conduct an initial pressure check of all integral fuel tanks and report findings to the government. The contractor will then completely de-seal all horizontal lower fuel tank surfaces and all fuel tank vertical bulkhead surfaces. After sealant is removed, the contractor will conduct a second pressure check and report findings to the government. Lastly, the contractor will completely de-seal the flight deck window frames. All work shall be completed in accordance with the publications and procedures listed below.

Phase 2 – The government will repair all deficient structures and fasteners that were identified and reported to the government during the leak check. The government will provide the contractor with an advance notice of the anticipated Phase 2 completion date.

Phase 3 – The contractor will prepare all fuel tank surfaces for sealant and apply sealant. All work shall be completed in accordance with the publications and procedures listed below.

The contractor shall establish and provide a warranty plan for the fuel tank portion to ensure all repair work and services are covered by the warranty. The warranty plan shall provide a warranty repair process such as procedures for processing, length of warranty from time of service and a point of contact between the contractor and the USCG. All warranty discrepancies shall be corrected in an expeditious manner.

3. CONTRACT REQUIREMENTS

The Coast Guard’s objective is to obtain services from a Federal Aviation Administration (FAA) Authorized Repair Center that is deemed to be acceptable to the Coast Guard and has experience in effectively repairing aircraft fuel tanks. The contractor shall be ISO 9000 compliant or have a quality system acceptable to the Coast Guard.

The contractor shall be responsible for supplying all tools, equipment, and materials listed in section 6 of this SOW.

The contractor shall comply with all federal, state and local environmental laws and regulations in the safe handling, storage and disposal of all hazardous material (HAZMAT).

The contractor shall complete Phase 1 in eighteen (18) calendar days upon being provided access to the aircraft. The contractor shall complete Phase 3 in eighteen (18) calendar days upon being provided access to the aircraft. The USCG desires for services to be completed as expeditiously as possible.

The Contractor shall maintain, at a minimum, one of the following: FAA, European Aviation Safety Agency (EASA), Department of Defense (DOD), OEM, Industry Standard Certification (i.e. National Aerospace and Defense Contractors Accreditation Program (NADCAP)) and/or USCG certifications for all work identified in the contract for the entire duration of this contract. The Contractor must notify the Contracting Officer verbally and in writing, not later than five (5) calendar days after certification forfeiture, and disclose all facts relevant to the forfeiture.

4. PUBLICATIONS AND PROCEDURES

To ensure the aircraft integral fuel tanks are repaired in accordance with the government’s current specifications and procedures, the contractor shall use the government furnished HC-27J Integral Fuel Tank Sealant Replacement / Flight Deck Window Frame Stripping checklist, technical orders, publications, and repair specifications. Any deviations must be approved by the USCG Contracting Officer.

Publications

AFTO 1-1-3 - Inspection and Repair of Aircraft Integral Tanks and Fuel Cells (General) CGTO 1C-27J-2-6 - Aircraft Dimensions Wing Frame and Rib Stations AFTO 1C-27J-3 - Structural Repair Manual CGTO 1C-27J-4 - Illustrated Parts Breakdown

Integral Fuel Tank Sealant Replacement Procedures

NOTE: Government personnel will remove and install all access panels and tank components.

1. Pressure test all fuel tanks to a maximum of 3.0 PSI.

a. Conduct leak detection test of all tank areas.

b. Record all leaking areas and report to government.

2. Protect and secure fuel tank components that are unable to be removed.

3. Completely de-seal all horizontal lower fuel tank surfaces and all fuel tank vertical bulkhead surfaces.

4. Rinse and clean all fuel tanks.

5. Remove protective equipment from all fuel tank components.

6. Conduct final cleaning of all fuel tank surfaces.

7. Pressure test all fuel tanks to a maximum of 3.0 PSI.

a. Conduct leak detection test of all tank areas.

b. Record all leaking areas and report to government.

8. Apply NAFTOSEAL-MC115 Adhesion Promoter to all fuel tank sealant surfaces and allow to cure.

9. Apply PR-1782 Class A Low Density Sealant and allow to cure.

a. Inspect sealant and fill in any and all voids.

10. Apply PR-1782 Class B Low Density Sealant and allow to cure.

a. Inspect sealant and fill in any and all voids.

11. Pressure test all fuel tanks to a maximum of 3.0 PSI.

a. Conduct leak detection test of all tank areas.

b. Record all leaking areas and report to government.

c. Correct any and all fuel tank sealant voids.

d. Repeat pressure testing and sealant application until pressure test indicates no leaks.

Integral Fuel Tank Sealant Replacement Procedures

1. Government personnel will install water protective barrier between window frames and flight deck.

2. Using no higher than 15,000 psi, remove all sealant from flight deck window frames.

3. Remove sealant debris.

5. INSPECTION AND ACCEPTANCE

The contractor Quality Assurance (QA) representative shall inspect all work performed on the aircraft fuel tanks prior to government’s final acceptance of the work. Any fuel leaks following the acceptance shall be addressed as a warranty item. The flight deck window frames will be inspected for complete removal of the sealant.

Final inspection and acceptance will be performed by ALC QA personnel for quantity, condition, and compliance with this SOW.

6. CONTRACTOR FURNISHED EQUIPMENT

The contractor shall provide all necessary materials, labor, tooling, fuel cell venting equipment, de-seal machinery, manual de-seal tools, potting/sealant compounds, consumable items required for sealant mixing/cleanup, tank access tools, fuel tank entry clearance certification, and ALC mandated Personal Protective Equipment.

7. GOVERNMENT FURNISHED EQUIPMENT

The government shall provide hangar space, fuel bowser, compressed air, all aircraft replacement parts, HC-27J Integral Fuel Tank Sealant Replacement / Flight Deck Window Frame Stripping Checklist, technical orders, publications, and repair specifications.

8. TERMS AND CONDITIONS

The contractor shall warranty that work performed shall be free from defects or leaks for at least ninety (90) calendar days after government completion of the first fuel event. Servicing aircraft with fuel for the first time may be multiple months after contractor completion of work. If leaks are detected after the aircraft has left ALC but still within the ninety-day warranty time frame, the travel and equipment shipping costs will be incurred by the contractor. Only contractor leak warranty repairs INCONUS will be incurred by the contractor.

9. TECHNICAL/REQUIREMENTS PERSONNEL CERTIFICATIONS

I certify this requirement meets the Government’s minimum need and that the supporting data, which forms a basis for this justification, is complete and accurate.

Christopher A. Walker, CWO2 (252) 335-6013 Date:

USCG ALC MRS/HC-27J Engineering