Attch

Solicitation N00019-09-R-0216 Amendment 0005

DEPARTMENT OF THE NAVY

NAVAL AIR SYSTEMS COMMAND

PATUXENT RIVER, MD 20670

STATEMENT OF WORK

for

P-3 AIRCRAFT SUSTAINMENT

09 June 2010

LIST OF APPENDICES

SECTION

TITLE

DATE

APPENDIX A

Acronyms 25 October 2009

APPENDIX B

SSI-K (outer wings) Replacement Drawings

APPENDIX C

Zone 5 Installation Drawings 09 June 2010

APPENDIX D

SSI-K (outer wings) and Zone 5 Installation Drawings

APPENDIX E

SSI-K (outer wings) BOM 09 June 2010

APPENDIX F

Zone 5 BOM

APPENDIX G

SSI-K (outer wings) and Zone 5 BOM

APPENDIX H

DIMPLE (Change 2) 19 July 2010

APPENDIX I

Government Furnished Property 25 October 2009

APPENDIX J

Fatigue Critical Parts

APPENDIX K

Center Wing Structures Replacement Drawings

APPENDIX L

Center Wing Assembly BOM 16 March 2010

APPENDIX M

Outer Wing Installation Drawings

APPENDIX N

Outer Wing Installation BOM

APPENDIX O

Block Modification Upgrade Program Plus Drawings

APPENDIX P

Block Modification Upgrade Program Plus BOM

APPENDIX Q

Miscellaneous Structures Replacement Drawings 09 June 2010

APPENDIX R

Miscellaneous Structures Replacement BOM 16 March 2010

APPENDIX S

P-3 Outer Wing Shoring Guide

APPENDIX T

P-3 Alignment and Symmetry Template

APPENDIX U

EP-3 ALD-9 Removal Requirements

APPENDIX V

P-3 Sustainment Inspection Data Package

TABLE OF CONTENTS

3TABLE OF CONTENTS

SCOPE

REFERENCED DOCUMENTS

52.1 Industry Standards

52.2 Other Documents

52.3 Source of Documents

PROGRAM OPERATIONS

53.1 Program Plans

53.1.1 Quality Assurance Plan

63.1.2 Configuration Management (CM) Plan

63.1.3 Risk Management Plan

63.1.4 Systems Safety Plan

63.1.5 Operations Security (OPSEC) Plan

73.1.6 Data Management (DM)

73.1.7 Flight Operations Plan

83.2 Program Coordination

83.2.1 Post-Award Conference

83.2.2 Program Management Review (PMR)

93.2.3 Technical Interchange Meeting (TIM)

93.2.4 AGTR/IMC Site Coordinator Office

93.3 Support Infrastructure (required per induction of aircraft or outer wing set)

93.3.1 Program Management

103.3.2 Program Planning and Control

103.3.3 Production Schedule

103.3.4 Data Management (DM)

103.3.5 Management and Accountability of Government Property

103.3.6 Subcontracts

103.3.7 Bonded Storeroom

113.3.8 Liaison Engineering

113.3.9 Technical Process Changes

113.3.10 Engineering Investigations

113.3.11 Technical Data Deficiencies

113.3.12 Other Program Data

123.3.13 Facilities

133.3.14 EVM/Cost Reporting

GENERAL AIRCRAFT REQUIREMENTS

144.1 Incoming and/or Recurring Aircraft Requirements

144.2 Disturbed Systems

144.3 Cannibalization

154.4 Aircraft Fuel

154.5 Inspection Requirements of Previous Repairs In Fatigue Critical Locations

154.6 Discrepancies

154.7 Conditional Inspection

154.8 Aircraft Final Processing

154.9 Aircraft Data Reports

154.9.1 Noted But Not Corrected (NBNC) Report

154.9.2 Wing Structural Alteration Report

154.9.3 Aircraft Custody/Change of Status Report

154.9.4 Aircraft Flight Summary Report

164.9.5 Aircraft Engine Management System Report

164.9.6 Aircraft Mishap Damage Report

164.9.7 90 Day Assessment Report

164.10 Personnel Qualifications

164.10.1 Non-Destructive Inspection (NDI)

164.10.2 Welders

PLANNED MAINTENANCE INTERVAL (PMI)

165.1 PMI Phase I

165.2 PMI Phase II

175.3 PMI Phase IIE

175.4 PMI Phase I (Fuselage and wing components)

175.5 PMI Phase II (Fuselage and wing components)

175.6 PMI Phase IIE (Fuselage and wing components)

175.7 PMI Wings

COMMON STRUCTURAL REPLACEMENT/INSTALLATION REQUIREMENTS

ZONE 5 INSTALLATION

187.1 Flight Hour Requirement

187.2 Installation Kit and Drawings

187.3 Shoring

197.4 Alignment and Symmetry

197.4.1 Zero Loading

197.5 Special Instructions

CENTER WING STRUCTURES REPLACEMENT (CWSR) (outer wings attached to fuselage)

198.1

198.2

218.3

218.4

218.5

CWSR (outer wings removed from fuselage)

229.1

229.2 Installation

229.3

229.4

239.5

SSI-K (outer wings)

2310.1

2310.2

2310.3

SSI-K (outer wings)/ZONE 5

2411.1

2411.2

2411.3

OUTER WING (OW) INSTALLATION

2412.1

2512.2

2512.3

2512.4

2512.5

EP-3 AIRCRAFT DELTA REQUIREMENTS

2513.1 CWSR Only

2513.2 All Structural Replacements/Installations

BLOCK MODIFICATION UPGRADE PROGRAM PLUS (BMUP+) DELTA REQUIREMENTS

2614.1 CWSR Only

2614.2 All Structural Replacements/Installations

MANAGEMENT AND ACCOUNTABILITY OF GOVERNMENT PROPERTY (GP)

1 SCOPE

This Statement of Work (SOW) describes the requirements for Planned Maintenance Interval (PMI), structural replacement and fabrication efforts pertaining to Special Structural Inspection – Kits (SSI-K), Center Wing Assemblies (CWA), Zone 5 kits, and outer wing installations and refurbishments on P-3C, EP-3, and NP-3 aircraft.

2 REFERENCED DOCUMENTS

2.1 Industry Standards

AMS-C-27725

ASTM E 399

ASTM B 645

AMS 4293

ASTM E8

ASTM B 557

2.2 Other Documents

COMNAVAIRFORINST 4790.2 series FAR, Federal Acquisition Regulation

DoD Manual 5220.22-M, National Industrial Security Program Operating Manual (NISPOM)

OPNAVINST 3432.1

DFARS, Defense Federal Acquisition Regulation Supplement Exhibit 8A, SECNAVINST 5510.36

NA 01-75PAA-2-1

NA 01-75PAA-3-1

NA 01-75PAA-3-2

NA-01-75PAA-IMP-6-3

NA 01-75PAC-4-5

NADEP Jax Dwg E10-21261

NADEP Jax Dwg E10-21262

MIL-HDBK-1021/1

2.3 Source of Documents

To obtain copies of applicable documents, consult the local Defense Contract Management Agency (DCMA) or forward requests to the Commanding Officer, Naval Air Technical Data & Engineering Service Command, NAS North Island, Bldg 90, P.O. Box 357031, San Diego, CA 92135-7031. The Contractor is responsible for obtaining any updates to the applicable documents for tasks herein.

3 PROGRAM OPERATIONS

3.1 Program Plans

3.1.1 Quality Assurance Plan

The Contractor shall develop and implement a quality assurance program to meet the level of quality system management addressed in COMNAVAIRFORINST 4790.2 series and ISO 9002, or equivalent, for quality assurance in production, installation, inspections, and aircraft maintenance. The Contractor shall develop and deliver a Quality Assurance Program Plan (QAPP). The plan shall include controls over manufacturing and production process control/techniques. The plan shall address control of tools, templates and shop aides, and Foreign Object Damage (FOD) prevention, to, at a minimum, ensure that these items are accounted for during the performance of contract requirements. The plan shall establish quality verification methods, to include Type I mandatory inspection requirements for safety-of-flight items classified as critical if found defective, as defined in Appendix H. The plan shall include identification of quality requirements on work documentation and mandatory verification of all safety-of flight items. An existing Contractor QAPP may be used if it complies with the above requirements. (CDRL A00C)

All subsidiary plans, associated documents, company specifications and/or quality records referenced by the QAPP shall be delivered to the Government upon request. The Contractor shall notify the Government of all changes to processes defined in the QAPP at Program Management Reviews.

3.1.2 Configuration Management (CM) Plan

The Contractor shall maintain a CM program. The Contractor may use MIL-HNDK-61A(SE) as a guide. The Contractor shall deliver a CM plan for the control of documentation, physical media, and physical parts applicable to the P-3 Sustainment Program. The Contractor shall comply with the applicable requirements of GEIA-649 (may use MIL-STD-973 as a guide). The contractor shall provide for NAVAIR representation on all change boards. (CDRL A00S)

3.1.3 Risk Management Plan

The Contractor shall maintain a risk management function to identify potential sources of technical, cost, or schedule risks and to determine risk levels. The contractor shall ensure that risk is factored into decisions for all areas of the program. Risk mitigation plans shall be developed for all moderate or high level risks.

The Contractor shall perform Risk Management in accordance with the NAVAIR Risk Management Guide or Contractor equivalent. Risk Management shall include, but not be limited to, risk identification, assessment, mitigation and recovery. (CDRL A00R).

3.1.4 Systems Safety Plan

The Contractor shall develop a written system safety plan. The plan must incorporate adequate general and specific safety requirements. The general safety requirements must contain policy, organization, methods of implementation, and the means to effect corrective actions. The specific safety requirements must state detailed safety instructions that the Contractor must comply with to ensure safety of personnel and Government property. The system safety program plan, at a minimum, shall address: housekeeping; fire prevention; mishap prevention; aircraft cleaning; portable fire extinguishers; fire protection; foreign object damage; handling; storage and use of compressed gas; certified tool control; aircraft towing; parking and mooring; grounding and bonding; fuel tank/cell repair operations; aircraft jacking; painting and paint removal; spray painting; welding; use and maintenance of work stands/platforms; sheltering of fueled aircraft; hoists and lifting devices; and flight safety.

3.1.5 Operations Security (OPSEC) Plan

The Contractor shall provide Operations Security (OPSEC) protection for all classified information (as defined in FAR 4.401) and sensitive information (as defined in Title 15, United States Code, Section 278g-3(d)(4)). Security policy, procedures, and requirements for classified information are provided in DoD Manual 5220.22-M, National Industrial Security Program Operating Manual (NISPOM). The Contractor shall use OPNAVINST 3432.1 and National Security Decision Directive (NSDD) 298 for the concept of OPSEC, and apply the framework for telecommunications security in Defense Federal Acquisition Regulation Supplement (DFARS) Clause 252.239-7016, as appropriate. The Contractor shall apply and use Distribution Statements following the provisions of Exhibit 8A, SECNAVINST 5510.36. In order to meet this requirement, the Contractor shall develop, implement and maintain a facility level OPSEC program to protect classified and sensitive information to be held, provided, used, handled, discussed, processed, stored, transmitted, or delivered at a Contractor’s or Subcontractor’s facilities. The Contractor is responsible for Subcontractor implementation of OPSEC requirements. The Contractor shall deliver an OPSEC plan. (CDRL A00P)

3.1.6 Data Management (DM)

The Contractor shall control the production and delivery of contract data and deliverables required under Section 3.1 of this SOW in accordance with all DD Form 1423 CDRLs. The Contractor shall maintain version/revision control of all Contractor-developed deliverable data. The Contractor shall produce, prepare, deliver and maintain up-to-date versions of all data specified in CDRLs in accordance with the instructions contained therein. If the Government determined that a deliverable(s) is (are) unacceptable, it will submit in writing the reasons for non-acceptance, detailing any correction requested. The Contractor shall submit a revised data item(s) to the Government within 30 working days following written notification.

3.1.7 Flight Operations Plan

The Contractor shall develop air and ground procedures that ensure the following requirements are met:

· Ensure that a Flight Operations Program is in effect to prevent injury to personnel and damage to aircraft in accordance with DFARS clause 252.228-7001 "Ground and Flight Risk," and NAVAIRINST 3710.1.

· Record files for ACO, as required in NAVAIRINST 3710.1.

· Develop and deliver procedures for the evacuation and protection of aircraft in the event of severe weather (hurricane, strong winds, etc.). The Contractor shall include provisions for sheltering, securing, or repositioning the aircraft, as well as for notifying the Administrative Contracting Officer of the actions taken.

· Publish an Air Operations Manual. The manual shall consist of written procedures for flight operations at the Contractor and in the local operating areas. The Air Operations Manual will cover, at least the following primary areas of concern and shall incorporate the requirements of OPNAVINST 3710.7 (Navy personnel) and NAVAIRINST 3710.1 (Personnel from the Contractor):

· Flight Management: The flight management section shall address flight scheduling to include the following:

· Procedures for obtaining approval for flights, including induction and functional check flights. In cases where a type of flight is conducted repeatedly for the same purpose, the approval may be for all flights of that specified type, having the same mission profiles.

· Ground Crew Requirements. This section will include information on the qualifications, certifications, and training programs of personnel involved in engine run-ups, aircraft tow operations, fuel service operations, and aircraft fire fighting and rescue operations. This section will also identify technical manuals and checklists that will be used in performing all functions for which technical data has been published. This includes towing, refueling, and scheduled and unscheduled maintenance. Technical manuals/checklists for the P-3 Depot Maintenance Program, as well as flight operations shall include:

· Procedures that ensure all changes, revisions and supplements are promptly posted in the basic technical data available.

· Provisions for determining weight and balance for each aircraft and flight.

· Procedures for issuance of certificates, licenses and permits.

· Procedures for the care and maintenance of life support equipment.

· Planning and Flight Mission Procedures: The planning and flight mission procedures section shall be developed around the following criteria:

· Mission profiles for each regularly conducted flight shall be covered in the flight operations procedures; include the establishment of specific geographic areas or point-to-point routes and flight following procedures for the conduct of flights.

· Mission profiles and specified geographical areas should make maximum use of ground radar and ground radio to monitor position and status of aircraft.

· Operational procedures at the Contractor’s facility shall include the following items. If the flight activity is physically located at a fully operational civil or military airfield that has these procedures in operation, the Contractor must comply with local directives and execute an agreement with the airfield authority. All procedures must meet Federal Aviation Administration (FAA) requirements and as a minimum include:

· Basic flight regulations, to include flight areas

· Weather minimums

· Traffic control tower requirements

· Filing of flight plans

· Standard Operating Procedures shall include:

· Radio failure procedures

· Gear malfunction procedures

· Aerodrome traffic procedures

· Emergency procedures for take-off and landing including procedures for the use of fire equipment.

· Minimum fuel procedures

· Diverts

· Noise abatement

· Severe Weather plans.

· Procedures for use of life support equipment.

3.2 Program Coordination

Unless otherwise specified, conferences/meetings shall be conducted at the Contractor or subcontractor’s facility.

3.2.1 Post-Award Conference

The Contractor shall conduct one Post-Award Conference approximately 60 days after contract award at the Contractor’s facility. The purpose is to allow the Contractor and the Government to establish lines of communication, set program objectives and priorities, and address any issues. The Contractor shall prepare and deliver an agenda (CDRL A00H) and meeting minutes (CDRL A00J).

3.2.2 Program Management Review (PMR)

3.2.2.1 PMR Presentation

The Contractor shall conduct a PMR three months after the Post Award Conference and quarterly thereafter. The Contractor shall prepare and deliver an agenda (CDRL A00H) and meeting minutes (CDRL A00J). The items for presentation and discussion at each PMR shall include, at a minimum:

a. A brief overview and status of the program objectives and the feasibility of obtaining them;

b. Updates to the Program Master Schedule;

c. An update and analysis of Technical Performance Measures and associated metrics;

d. An assessment of the program schedule and risks, including missed milestones and corrective action plans;

e. A master critical path analysis and summary of work-arounds performed;

f. Status of outstanding action items from previous PMRs

g. Results from the previous period and detailed plans for the next period;

h. A summary of program data, including production status, engineering status and issues; and

i. Status and discussion of open action items resulting from the previous PMRs, milestone presentations, and technical coordination meetings.

j. Over and Above labor and material funding status.

k. Copies of all presentation material (e.g., charts, graphs, etc.). (CDRL A00J)

3.2.2.2 Program Master Schedule

The Contractor shall establish and maintain an integrated production schedule for all inducted aircraft and wing sets, to include the coordination and phasing of all production schedules, tools and facilities availability, material and parts deliveries, and manpower resources. The Contractor shall deliver current production progress and status, tracking of critical path items and workaround planning. (CDRL A00R)

3.2.3 Technical Interchange Meeting (TIM)

The Contractor shall conduct monthly TIMs to facilitate identification and resolution of technical issues (e.g., engineering, production, safety, ILS, etc.) to minimize potential impact to the program. The Contractor shall conduct a weekly telephone conference to discuss technical and production issues with representatives from PMA-290, the Authorized Government Technical Representative (AGTR)/Integrated Maintenance Concept (IMC) Site Coordinator, and Defense Contract Management Agency (DCMA) representatives. The Contractor shall prepare and deliver an agenda (CDRL A00H) and meeting minutes (CDRL A00J).

3.2.4 AGTR/IMC Site Coordinator Office

The Contractor shall provide office space at its facility with work stations for up to three Government/Contractor Support Services (CSS) representatives equipped with all of the following minimum equipment, facilities and furniture:

· Standard desk per person.

· Telephone, call transfer and conference call capabilities using a dedicated line per person.

· Fax machine with dedicated telephone line.

· Laser printer.

· Personal Computer: Current Industry Standards including most current version of MS-Windows or equivalent, CD-ROM, 2 MB video RAM, 17” color monitor, mouse, keyboard, and interchangeable, Microsoft Office 2003 or equivalent and interchangeable, E-Mail for Windows or equivalent and Microsoft Project.

· 150 square foot minimum floor space in a quiet and secure environment per person.

· Parking facility close to office space provided.

· All personal protective equipment necessary to perform routine duties in industrial areas per person.

3.3 Support Infrastructure (required per induction of aircraft or outer wing set)

The Contractor shall provide support personnel (i.e., non-touch labor) and facilities necessary to implement all program plans (developed under Section 3.1 of this SOW) and to manage and execute all support efforts necessary for the basic and over and above requirements ordered for each induction of aircraft or outer wing set. [Note – touch labor is defined in Note (1) of Section B of the contract.] In addition to those detailed in Section 3.3 of this SOW, support infrastructure functions include scheduling, financial control, business management, contracts management, data entry and administration, production support, quality support, material resource planning, tool/toolroom management, supervision, and production set-up and removal tasks.

3.3.1 Program Management

The Contractor shall manage all technical and contractual performance, including program planning and control, risk management, reliability, maintainability, Integrated Logistics Support (ILS), cost, schedule, and data delivery requirements.

3.3.2 Program Planning and Control

The Contractor shall plan, control, and manage contract performance, production, critical path items, and ILS milestones on an ongoing basis. A single individual shall be designated by the Contractor to serve as Program Manager for performance under the contract. This individual shall have cognizance and full responsibility for overall performance and resourcing, and shall serve as the primary management representative in all matters relating to contract performance.

3.3.3 Production Schedule

The Contractor shall establish and maintain a production schedule for each aircraft or wing set in work. The production schedule shall include milestones and all significant tasks, events and activities required to effectively manage progress and technical performance. The schedule shall be to at least a level-3 work breakdown structure. (CDRL A008)

3.3.4 Data Management (DM)

The Contractor shall control the production and delivery of contract data and deliverables required under Section 3.3 of this SOW in accordance with all DD Form 1423 CDRLs. The Contractor shall maintain version/revision control of all Contractor-developed deliverable data. The Contractor shall produce, prepare, deliver and maintain up-to-date versions of all data specified in CDRLs in accordance with the instructions contained therein

3.3.5 Management and Accountability of Government Property

A GFP list is provided in Appendix I entitled “Government Furnished Property” for the performance of the SOW requirements herein. In addition to complying with the requirements of FAR Part 45 for all GFP, the Contractor shall ensure all applicable GFP items are properly maintained and calibrated.

3.3.6 Subcontracts

3.3.6.1 Subcontract Management

The Contractor shall be solely responsible for the performance and quality of all subcontractor work. The Contractor shall ensure that contractual requirements are disseminated down to the subcontract level. The Contractor shall identify and monitor subcontractor technical, quality, schedule, and milestone achievement on an ongoing basis throughout the duration of each subcontracted effort.

3.3.6.2 Subcontract Monitoring

The Contractor shall make provisions for Government representatives to participate in visits to subcontractor facilities, technical working groups, and periodic reviews for the purpose of observing work in progress. Five (5) days advance notice shall be given to the COR prior to planned subcontractor visits.

3.3.7 Bonded Storeroom

The Contractor shall record items that have been removed from the aircraft by Bureau Number (BuNo), and retain the items in bonded storerooms until Government disposition. The storeroom shall be co-located with the aircraft production area.

3.3.8 Liaison Engineering

The Contractor shall provide liaison engineering to support each technical effort as necessary. The Liaison Engineering personnel shall be knowledgeable of NAVAIR and industry standards and specifications, format and content of NAVAIR technical publications, and industry-accepted aircraft engineering and maintenance practices. Duties of the Liaison Engineering personnel shall include the following:

a. Provide technical support to program management;

b. Provide technical support to quality control, material, manufacturing, and other personnel affecting the program;

c. Provide technical oversight for all process changes affecting the program;

d. Perform analysis, as required, to disposition material discrepancies;

e. Serve as the principal interface to the Government to obtain clarification of technical requirements and ensure that such requirements are implemented on the program;

f. Provide technical oversight of subcontractor engineering, manufacturing and rework;

g. Participate in Program Management Reviews; and

h. Participate in Technical Interchange Meetings.

3.3.9 Technical Process Changes

Alternate technical process methods may be identified that improve the processes of the core sustainment items (e.g., PMI, SSI-K, Zone 5, and CWA installations) without degrading the aircraft technical performance. In such instances, the Contractor may request approval of the proposed alternate process by submitting all substantiating data to PMA-290. (CDRL A00A)

3.3.10 Engineering Investigations

The Contractor shall immediately inform the Government and NAVAIR Engineering of any discovered failure and/or abnormal condition that may be safety of flight related or flight critical in regard to fleet aircraft. The Contractor’s initial notification shall be accomplished via telephone or fax and the formal notification shall be handled via the In-Service Support Center (ISSC) Jacksonville (P-3 Fleet Support Team). The Navy will assess defects discovered for possible Engineering Investigations (EI) or potential Bulletins regarding safety of flight issues and tracking and trend analysis. (CDRL A00D)

3.3.11 Technical Data Deficiencies

Since technical manual and drawing deficiencies may be encountered, the Contractor shall possess reverse engineering capabilities in order to perform the tasks of this SOW, specifically in the areas of fabrication, assembly, and manufacturing processes. The Contractor shall identify any technical data deficiencies by delivering a Technical Publication Deficiency Report (TPDR). (CDRL A009)

3.3.12 Other Program Data

3.3.12.1 Request for Deviation

The Contractor shall deliver requests for deviation as necessary. (CDRL A00L)

3.3.12.2 Request for Waiver

The Contractor shall deliver requests for waivers as necessary. (CDRL A00M)

3.3.12.3 Integrated Master Schedule

The Contractor shall deliver an integrated master schedule. (CDRL A00U)

3.3.12.4 Funds Expenditure Report

The Contractor shall deliver a funds expenditure report. (CDRL A00V)

3.3.13 Facilities

The Contractor shall provide facilities to support contract performance related to each induction of aircraft or outer wing set, in accordance with the following requirements:

· Be capable of accomplishing the required P-3 depot work, while meeting all operational time, noise, and local environmental regulations with no impact on the P-3 effort requirements and schedules.

· Meet the security requirements of OPNAVINST 5530.14, including the special requirements for aviation assets.

· Aerodrome

· Provide a facility sufficient to conduct safe operations.

· Provide tower and communications facility that provides radio communications between the tower and aircraft during all ground operations (e.g. taxi, take-off, landings).

· Capable of immediately alerting fire fighting and medical facilities.

· Airfield

· Permit all P-3 aircraft to land, taxi, and take-off safely as described in applicable NATOPS Manual. Surfaces where takeoffs, landings, taxiing, parking, and towing occur must be paved with Portland cement, concrete or asphalt so as to accept operations at maximum gross weight landings of P-3 Series aircraft.

· Taxi ways that are in compliance with MIL-HDBK-1021/1 criteria for Class B runways.

· Include a parking apron that includes areas for outside work, engine run-up, parking, and temporary storage. The minimum safe clearance between maneuvering aircraft and other fixed or moving obstructions shall be 10 feet. Where aircraft move under their own power, spacing shall be adequate to protect against propeller blast and to provide interior and peripheral taxi-lanes for aircraft movement. Geometry and surfaces shall meet MIL-HDBK-1021/1 criteria.

· Mooring eyes shall be provided over the entire apron and shall conform to the requirements established in United Facilities Guide Specification (UFGS). The Contractor shall have one static grounding point with a resistance of 10,000 Ohms or less at each parking space. Minimum grade is .5% and maximum grade is 1.5%.

· Facilities shall enable the Contractor to swing, compensate, and calibrate all P-3 aircraft compasses.

· Contractor Maintenance Facilities

· Minimum clearance in the maintenance hangar between aircraft or between building structure and the aircraft shall be 5 feet when the aircraft is positioned in its final maintenance spot.

· Minimum hangar door clearance height shall be adequate to safely move P-3 aircraft in and out of hangar.

· Minimum ceiling clearance height shall be adequate to accommodate all P-3 aircraft configurations and safely use hoisting equipment.

· Hangar floor load capacity shall be able to completely and safely hangar P-3 aircraft.

· One power service point per aircraft dock with the following capabilities, 60 AMP, 240 VAC, 60 HZ, 3 Phase, 1 Outlet, 200 VAC, 400 HZ Aircraft Cable, 480 VAC, 100 AMPS, 60 HZ, 3 Phase, 2 Outlets, 115 VAC, 400 HZ, 1 Phase, 1 Outlet, 120 VAC, 60, HZ 20 AMPS, 1 Phase, 2 Outlets

· A minimum of one flush type-grounding receptacle shall be provided for each aircraft dock in the hangar. Resistance to ground shall not exceed 10 ohms.

· Hangar spaces or positions at which disassembly or assembly of the aircraft occurs shall have at a minimum a 2-ton over-head hoist capability or support equipment to provide this capability.

· All aircraft docks/positions shall have shop air with a minimum pressure of 90 PSI, a minimum flow rate of 60 CFM and be water free.

· Maintenance hangars shall comply with National Fire Protection Agency (NFPA) regulations

· Aircraft Painting and Corrosion Control Hangar

· The hangar shall comply with NFPA regulations.

· Relative humidity within paint facility shall be maintained from 50% to 80%.

· Cleaning and Stripping Bay Requirements: The Cleaning and Stripping Bay shall meet all applicable local, state, and federal environmental and occupational regulations and requirements.

· Work bays in which cleaning and stripping are to be accomplished shall be separate and isolated from work bays in which painting and curing are to be accomplished.

· Painting and Coating Bay Requirements: The Painting and Coating Bay shall meet all applicable local, state, and federal environmental and occupational regulations and requirements.

· The temperature within the paint facility shall be maintained at a minimum of 60 degrees F.

· Battery Storage Facilities

· The Contractor shall provide a battery storage facility that conforms to the following:

· Complies with NFPA regulations

· Capable of storing all aircraft batteries per NAVAIR 17-15-BAD-1

· Breathable Gaseous Oxygen And Gaseous Nitrogen

· The Contractor facilities shall have the capability to provide sufficient quantities of breathable gaseous oxygen and gaseous nitrogen for servicing the P-3 aircraft.

3.3.14 EVM/Cost Reporting

3.3.14.1 EVM

The contractor shall implement an integrated management system that is compliant with industry guidelines for EVM Systems (EVMS) ANSI/EIA-748-B. The Integrated Master Schedule (IMS) and Cost Performance Report (CPR) shall be developed, maintained, updated, and delivered (CDRL A0AA and CDRL A0AB). Performance data for Firm Fixed Price (FFP) CLINs do not require EVM reporting. Reporting levels for the CPR shall reflect the WBS level(s) employed for the Contractor Cost Data Reporting (CCDR) per SOW paragraph 3.3.14.3.

3.3.14.2 Subcontract Cost/Schedule Management and Reporting

The contractor shall flowdown cost, schedule, management, and reporting requirements to its subcontractors for the entire contract technical scope of work. EVMS flow down to contracts of less than $20M in then year dollars or FFP subcontracts (of any dollar value) is a risk-based decision to be made by the contractor. The contractor shall apply the requirements of the IMS (CDRL A0AA) and the requirements of the CPR (CDRL A0AB) to subcontracts at or exceeding $20M in then year dollars. The contractor shall manage all subcontracts (to include the timely award of the subcontract), integration of the subcontractor’s plans into appropriate schedules, and monitoring of subcontractor’s staffing plans (to include the execution of the staffing plans to the required levels with the required skills). Subcontractor staffing plans and actual staffing achievements shall be either integrated into the prime contractor’s CPR Format 4 or explained in a similar format in CPR Format 5. Sufficient detail necessary to manage subcontractors’ effort shall be included in the Prime’s IMS. The contractor shall ensure the validity of the subcontractor’s schedule data, including demonstrating effective methods for incorporating schedule from subcontractors into the contractor IMS. Special attention shall be applied to the technical accomplishment of the subcontractor’s critical tasks. The contractor shall conduct critical path analyses of the tasks and report problem areas and corrective actions required to eliminate or reduce schedule impact to the Government.

3.3.14.3 CCDR

In accordance with DFAR 215.403-5, the contractor shall deliver contract cost estimates using the CWBS dictionary. The contractor shall systematically collect and deliver actual contract costs to provide DoD cost analysts with needed data to estimate future costs. (CDRL A00W, A00X, and A00Y)

3.3.14.4 Contract Funds Status Report (CFSR)

The contractor shall deliver the CFSR for (non-FFP) CLINs. (CDRL A00Z)

4 GENERAL AIRCRAFT REQUIREMENTS

4.1 Incoming and/or Recurring Aircraft Requirements

If the aircraft is input in accordance with Section F of the Contract, the Contractor shall preserve the aircraft in accordance with NAVAIR 01-75PAA-IMP-6-3 until induction. After aircraft input at the Contractor’s facility, the Contractor shall:

a. Attend incoming post flight briefing in accordance with Appendix H, paragraph 2-1.1;

b. Screen and maintain aircraft logbooks and records in accordance with Appendix H, paragraph 2-1.2;

c. Inventory aircraft equipment in accordance with Appendix H, paragraph 2-1.3;

d. Inventory and store survival and loose equipment in accordance with Appendix H, paragraph 2-1.4;

e. Perform hydraulic system contamination check in accordance with Appendix H, paragraph 2-1.5;

f. Perform fuel systems contamination check in accordance with Appendix H, paragraph 2-1.6;

g. Conduct engine performance runs in accordance with Appendix H, paragraph 2-1.7;

h. Tow, jack, hoist, and moor the aircraft in accordance with Appendix H, paragraph 2-1.8;

i. Perform aircraft fuel leak processing (required for PMI events only)in accordance with Appendix H, paragraph 2-1.9;

j. Perform aircraft preservation in accordance with Appendix H, paragraph 2-1.10;

k. Make the aircraft hangar safe in accordance with Appendix H, paragraph 2-1.11; and

l. Rotate propellers in accordance with Appendix H, paragraph 2-1.12.

4.2 Disturbed Systems

When an aircraft system’s integrity has been disturbed, as part of or incidental to contract performance, the Contractor shall perform all maintenance actions required by the appropriate P-3 technical manuals and CNAF INST 4790.2 series. Functional checks of disturbed systems are only a requirement for safety of flight systems.

4.3 Cannibalization

Cannibalization of any aircraft part shall require AGTR/IMC Site Coordinator review and approval prior to cannibalization. The cost of approved cannibalization man-hours and materials, when performed to correct a defect or action caused by the Contractor will not be charged directly or indirectly to the Government.

4.4 Aircraft Fuel

The Government will provide the fuel necessary to refill all fuel tanks less the amount of usable fuel that was de-fueled at time of induction. The Government will only pay for one de-fueling and one refueling of the aircraft unless a discrepancy not related to the Core Sustainment Item is discovered or otherwise exists (i.e., engine and/or propeller). Any fuel required to troubleshoot, verify, or accomplish an additional Functional Flight Check shall be Government Furnished. Should the aircraft require any repairs to the fuel tanks subsequent to the refueling, the contractor will bear all associated costs excluding cost of fuel if it is determined that the Contractor failed to properly repair the fuel tanks thereby requiring the de-fueling of the tanks for additional repairs.

4.5 Inspection Requirements of Previous Repairs In Fatigue Critical Locations

The Contractor shall perform inspection requirements of previous repairs in fatigue critical locations in accordance with Section 15 of Appendix H.

4.6 Discrepancies

The Contractor shall follow the process in DFARS 252.217-7028 “Over and Above Work” and 5252.217-9507 “Over and Above Work Requests” for discrepancies found during a Core Sustainment Item.

4.7 Conditional Inspection

The Contractor shall notify the ACO or PCO in the event a conditional inspection is required.

4.8 Aircraft Final Processing

The Contractor shall perform the following:

a. De-preservation of the aircraft in accordance with Appendix H, paragraph 10-1.1

b. Disturbed systems check in accordance with Appendix H, paragraph 10-1.2

c. Aircraft special inspections in accordance with Appendix H, paragraph 10-1.3

d. Engine performance runs in accordance with Appendix H, paragraph 10-1.4

e. Fuel leak check in accordance with Appendix H, paragraph 10-1.5

f. Weight and balance requirements in accordance with Appendix H, paragraph 10-1.6

g. Inventory, logs, and records requirements in accordance with Appendix H, paragraph 10-1.7

h. Hydraulic system contamination check in accordance with Appendix H, paragraph 10-1.8

i. Requirements to make the aircraft ready for flight in accordance with Appendix H, paragraph 10-1.9

j. FCF requirements in accordance with Appendix H, paragraph 10-1.10

4.9 Aircraft Data Reports

4.9.1 Noted But Not Corrected (NBNC) Report

The Contractor shall deliver an NBNC report. (CDRL A001)

4.9.2 Wing Structural Alteration Report

The Contractor shall deliver a wing structural alteration report. (CDRL A004)

4.9.3 Aircraft Custody/Change of Status Report

The Contractor shall deliver an aircraft custody/status report. (CDRL A007)

4.9.4 Aircraft Flight Summary Report

The Contractor shall deliver an aircraft flight summary report. (CDRL A00B)

4.9.5 Aircraft Engine Management System Report

The Contractor shall deliver an aircraft engine management system report. (CDRL A00E)

4.9.6 Aircraft Mishap Damage Report

The Contractor shall deliver an aircraft mishap damage report. (CDRL A00F)

4.9.7 90 Day Assessment Report

The Contractor shall deliver a 90 day assessment report. (CDRL A00G)

4.10 Personnel Qualifications

4.10.1 Non-Destructive Inspection (NDI)

The Contractor shall provide Level II and Level III NDI personnel per American Society for Non-Destructive Testing (or equivalent) certification procedures and perform NDI as required by the Government.

The Contractor shall establish NDI operations and the qualifications for the minimum NDI techniques as follows:

· Eddy Current

· Fluorescent Penetrant – perform in accordance with American Society for Testing and Materials (ASTM) E1417, use Type I, methods c or d, sensitivity level 4

· Magnetic Particle

· Radiographic

· Ultrasonic

4.10.2 Welders

The Contractor shall provide welding capabilities with personnel who are certified per American Welding Society, or equivalent, certification procedures. The Contractor shall:

· Establish written procedures for welding operations, qualifications, and safety precautions; and

· Maintain a current list of all certified welders.

5 PLANNED MAINTENANCE INTERVAL (PMI)

5.1 PMI Phase I

The Contractor shall perform PMI in accordance with the requirements of Table 1 and 4 of Appendix H, as applicable to the aircraft type (i.e., P-3C, NP-3, or EP-3). The “All TMS/C Code” column of each table reflects the applicability of each PMI requirement to aircraft type.

5.2 PMI Phase II

The Contractor shall perform PMI in accordance with the requirements of Table 1 and 6 of Appendix H, as applicable to the type of aircraft (i.e., P-3C, NP-3, or EP-3). The “All TMS/C Code” column of each table reflects the applicability of each PMI requirement to aircraft type.

5.3 PMI Phase IIE

The Contractor shall perform PMI in accordance with the requirements of Table 1 and 7 of Appendix H, as applicable to the type of aircraft (i.e., P-3C, NP-3, or EP-3). The “All TMS/C Code” column of each table reflects the applicability of each PMI requirement to aircraft type.

5.4 PMI Phase I (Fuselage and wing components)

The Contractor shall perform PMI in accordance with the requirements of Table 2 and 5 of Appendix H, as applicable to the type of aircraft (i.e., P-3C, NP-3, or EP-3). The “All TMS/C Code” column of each table reflects the applicability of each PMI requirement to aircraft type.

5.5 PMI Phase II (Fuselage and wing components)

The Contractor shall perform PMI in accordance with the requirements of Table 2 and 8 of Appendix H, as applicable to the type of aircraft (i.e., P-3C, NP-3, or EP-3). The “All TMS/C Code” column of each table reflects the applicability of each PMI requirement to aircraft type.

5.6 PMI Phase IIE (Fuselage and wing components)

The Contractor shall perform PMI in accordance with the requirements of Table 2 and 9 of Appendix H, as applicable to the type of aircraft (i.e., P-3C, NP-3, or EP-3). The “All TMS/C Code” column of each table reflects the applicability of each PMI requirement to aircraft type.

5.7 PMI Wings

The Contractor shall perform PMI in accordance with the requirements of Table 3 of Appendix H, as applicable to the type of aircraft (i.e., P-3C, NP-3, or EP-3). The “All TMS/C Code” column of each table reflects the applicability of each PMI requirement to aircraft type.

6 COMMON STRUCTURAL REPLACEMENT/INSTALLATION REQUIREMENTS

The following requirements and instructions apply to maintenance events in paragraphs 7 through 14.

a. Components or structure salvaged for re-use during disassembly shall be cleaned, visually inspected, preserved and prepared for reinstallation. Non-salvaged components may be cleaned for fit check and visually inspected for Section 3.3.10 compliance.

b. The Contractor shall make work/no work decisions in accordance with Section 16 “Serviceability Requirements” of Appendix H.

c. For those areas where material is removed and replaced, including plank #9 in paragraph 8.2(e) and 9.2(e), the Contractor is responsible for delivering the aircraft leak free. The Contractor shall report to the AGTR/IMC Site Coordinator all other leaks noted in other areas of the aircraft deemed to be safety of flight related. All remaining leaks and seeps that are not safety of flight related will be returned to the squadron as NBNC.

d. The Contractor shall paint external surfaces of replaced material per FRCSE Drawing E10-21261. The Contractor shall reseal/paint all aircraft surfaces and components from which paint was removed, or that require refinishing incidental to the paint removal process, after priming process has occurred. Finish colors are not required to exactly match existing aircraft color due to fading and age of existing paint finish.

e. The aircraft must be returned to the Navy with the wing alignment unchanged from the incoming condition or improved based on the data given in NA 01-75PAA-3-2 Figure 1-2. For incoming aircraft prior to disassembly and outgoing aircraft, the Contractor shall jack and level the aircraft in accordance with NA 01-75PAA-2-1 and perform alignment and symmetry checks in accordance with NA 01-75PAA-3-2. The contactor shall record measurements using Appendix T – “Alignment and Symmetry Template” data sheets and determine if aircraft is within allowable tolerance. Alignment checks shall be performed on the basic airframe structure, power plant, nacelles and landing gear. Report all out of tolerance conditions to the PMA-290 for disposition. The incoming and outgoing aircraft alignment and symmetry results shall be delivered to the government (CDRL A00N) using Appendix T – “Alignment and Symmetry Template” data sheets upon completion of the shoots.

7 ZONE 5 INSTALLATION

7.1 Flight Hour Requirement

The system engineering requirements for Stand-alone Zone 5 replacement are designed to provide additional aircraft flight hours of service equal to that of the SSI-K or ESSI, as appropriate. Except as provided in the GFR Clause, if the Contractor damages Government property during performance of the requirements herein, the Contractor shall repair or replace the property at the discretion of PMA-290 at no additional cost to the Government. In the event of a repair, the Contractor shall design a repair to provide a minimum fatigue life equal to the fatigue life of the SSI-K/ESSI material with a minimum of 7500/5000 hrs for SSI-K/ESSI respectively. At no additional cost to the Government, the Contractor shall substantiate that the flight hour requirement is met with the designed repair through static and fatigue analysis and deliver the results to the Government for approval.

7.2 Installation Kit and Drawings

The Contractor shall disassemble and remove existing structure on the aircraft to allow for the installation of a Government-furnished kit. The Contractor shall install the kit items, listed in Appendix F – “Zone 5 BOM”, in accordance with the installation drawings listed in Appendix C – “Zone 5 Installation Drawings”.

7.3 Shoring

The Contractor shall support the fuselage and wings in such a manner that the aircraft alignment is maintained during installation. Support the fuselage in the following locations: (Actual shoring locations may be varied slightly depending on circumstances when approved by Government Engineering.)

a. A double cradle at FS 288/323. (Instead of the double cradle at FS 288/323. A single cradle at FS 185 and a single cradle at FS 323 may be used if access to the Auxiliary Power Unit (APU) compartment is needed to perform repairs.)

b. A single cradle at FS 477 (just aft of bomb bay door).

c. A single cradle at FS 553 (just forward of the center wing).

d. A double cradle at the following locations:

1. FS 716/ FS 749 (Ensure this piece does not obscure alignment point 14.)

2. FS 806 / FS 825.

3. FS 882/ FS 901.

e. A single cradle at FS 1117. This station support is for safety only and shall be snug against the fuselage but not lifting it.

f. The horizontal tail must be supported with at least one tripod (and contour board) on each side if conditions such as strong winds (greater than 5 knots) or other conditions exist that may result in fuselage misalignment.

g. Shore the wings in at least 5 locations, as required to maintain outer wing alignment and access for structure replacement.

7.4 Alignment and Symmetry

The Contractor shall jack and level the aircraft in accordance with NA 01-75PAA-2-1 and measure the aircraft using a laser based system at a minimum of five times during the process (Measuring landing gear points are not required for steps 7.4(a) and 7.4(e).):

a. During induction while fully assembled in accordance with NA 01-75PAA-3-2 Figure 1-2.

b. During wing shoring placement to achieve Zone 5 spreadsheet calculated station heights.

c. Prior to drilling the replacement rear beam components to ensure wing has remained zero loaded per Section 7.4.1.

d. After drilling rear beam and prior to drilling planks, also to ensure the wing has remained zero loaded per Section 7.4.1.

e. After final buildup and prior to fuelling in accordance with NA 01-75PAA-3-2 Figure 1-2.

7.4.1 Zero Loading

Zero loading of the wing is determined by performing a laser alignment shoot of each shoring location at the forward edge of the shoring at the plank #1 fwd edge and entering the results into a spreadsheet such as the one supplied Appendix S – “Zone 5 Alignment and Symmetry Template.” The spreadsheet generates required height of the shoring to place the wing in the zero load state.

7.5 Special Instructions

a. Parts and components that are removed for the structures replacement that are not part of the Government furnished kit shall be salvaged and re-installed following completion of the Zone 5 Structures Replacement.

b. The Contractor shall install the Main Landing Gear (MLG) actuator fitting repair described in Drawing 982340. If the repair was previously installed during SSI-K, the Contractor shall reinstall the repair.

8 CENTER WING STRUCTURES REPLACEMENT (CWSR) (outer wings attached to fuselage)

8.1 Flight Hour Requirement

The system engineering requirements for Stand-alone Center Wing Assembly (CWA) replacement are designed to provide additional aircraft flight hours of service equal to that of the SSI-K or ESSI, as appropriate. Except as provided in the GFR Clause, if the Contractor damages Government property during performance of the requirements herein, the Contractor shall repair or replace the property at the discretion of PMA-290 at no additional cost to the Government. In the event of a repair, the Contractor shall design a repair to provide a minimum fatigue life equal to the fatigue life of the SSI-K/ESSI material with a minimum of 7500/5000 hrs for SSI-K/ESSI respectively. At no additional cost to the Government, the Contractor shall substantiate that the flight hour requirement is met with the designed repair through static and fatigue analysis and deliver the results to the Government for approval.

8.2 Installation Kit and Drawings

a. The Contractor shall disassemble and remove existing structure on the aircraft to allow for the installation of a Government furnished kit. The Contractor shall install the kit items listed in Appendix L – “Center Wing Assembly BOM” in accordance with the installation drawings listed in Appendix K – “Center Wing Structures Replacement Drawings.” The Contractor shall install the items listed in Appendix R – “Miscellaneous Structures Replacement BOM” in accordance with the drawings listed in Appendix Q – “Miscellaneous Structures Replacement Drawings.” (Note: Only drawings 982304 and 982329 of Appendix Q apply to the CWSR.)

b. The Government-furnished CWA will be delivered to the Contractor without the holes drilled and without ForceTec® fasteners installed in the tank 5 access panel. The Contractor shall drill the required holes and install ForceTec® fasteners per Appendix K – “Center Wing Structures Replacement Drawings.”

c. The Government-furnished CWA will be delivered without the over-wing fairing holes at the attach points. The Contractor shall drill the required holes per Appendix K – “Center Wing Structures Replacement Drawings.”

d. The Government-furnished CWA will be delivered without the stores fitting holes drilled.