Att_(1)_PWS_DRAFT_16_May_16.pdf

DRAFT

PERFORMANCE WORK STATEMENT

FOR

DEPOT-LEVEL REPAIR

OF

NAVAIR

KC-130J QUICK ENGINE CHANGE ASSEMBLIES

(AE2100D3 ENGINES)

16 May 2016

Solicitation Number

N00019-16-R-0013

Approved by: __________________________________________

DISTRIBUTION STATEMENT A. Approved for public release

Performance Work Statement

TABLE OF CONTENTS

PWS REVISION HISTORY ---------------------------------------------------------------------------------------------------- 5

1.0 SCOPE -------------------------------------------------------------------------------------------------- 6

1.1 Weapon System Description and Use ----------------------------------------------------------------------------- 6

1.2 Support Concept -------------------------------------------------------------------------------------------------------- 6

1.2.1 Operational Concept ---------------------------------------------------------------------------------------------------------------------- 6

1.2.2 Maintenance Concept --------------------------------------------------------------------------------------------------------------------- 6

2.0 APPLICABLE DOCUMENTS --------------------------------------------------------------------- 6

2.1 Government Documents ---------------------------------------------------------------------------------------------- 7

2.2 Kuwait Air Force Specific Documents ------------------------------------------------------------------------------ 7

2.3 Other Documents ------------------------------------------------------------------------------------------------------- 7

3.0 GENERAL REQUIREMENTS --------------------------------------------------------------------- 7

3.1 Quality Management System ---------------------------------------------------------------------------------------- 7

3.2 Operations Security ---------------------------------------------------------------------------------------------------- 8

3.3 Project Management -------------------------------------------------------------------------------------------------- 8

3.3.1 Project and Risk Management. --------------------------------------------------------------------------------------------------------- 8

3.3.2 Project Manager. --------------------------------------------------------------------------------------------------------------------------- 8

3.4 Hazardous Material and Waste ------------------------------------------------------------------------------------- 8

3.5 Package, Handling, Shipping, and Transportation -------------------------------------------------------------- 8

3.5.1 Contractor Shipping Requirements QECAs and Components. ---------------------------------------------------------------- 8

3.5.2 Shipping, Packaging, Storage, and Containers. ------------------------------------------------------------------------------------ 8

3.5.3 Government Furnished Property Shipping. ----------------------------------------------------------------------------------------- 8

3.6 Export Control Licenses ----------------------------------------------------------------------------------------------- 8

3.7 Engine Transaction Reporting --------------------------------------------------------------------------------------- 8

3.8 Information Assurance ------------------------------------------------------------------------------------------------ 9

4.0 PROJECT REQUIREMENTS (CLINS 0X01 AND 0X02) ------------------------------------ 9

4.1 Management Plan ------------------------------------------------------------------------------------------------------ 9

4.2 Meetings and Reviews ------------------------------------------------------------------------------------------------- 9

4.2.3 Agenda. ------------------------------------------------------------------------------------------------------------------------------------- 10

4.2.4 Meeting Minutes. ------------------------------------------------------------------------------------------------------------------------ 10

4.3 Airworthiness and Configuration Management -------------------------------------------------------------- 10

4.3.1 Airworthiness Certification Authority. --------------------------------------------------------------------------------------------- 10

4.3.2 Configuration Changes. ---------------------------------------------------------------------------------------------------------------- 10

4.3.3 Technical Variances and Deviations. ----------------------------------------------------------------------------------------------- 10

4.4 ENGINEERING AND TECHNICAL SERVICES ---------------------------------------------------------------------- 11

4.4.1 Technical Services -------------------------------------------------------------------------------------------------- 11

5.0 GENERAL REPAIR REQUIREMENTS ----------------------------------------------------------- 11

5.1 Repairs ------------------------------------------------------------------------------------------------------------------- 11

5.2 Security of Government Property -------------------------------------------------------------------------------- 13

5.3 Cannibalization -------------------------------------------------------------------------------------------------------- 13

5.4 Condemnation --------------------------------------------------------------------------------------------------------- 13

5.5 Disposition of Material ---------------------------------------------------------------------------------------------- 13

6.0 INDUCTION, DISASSEMBLY, AND ASSEMBLY OF THE QECA (CLIN 0X03) --- 13

6.1 Receipt of QECAs ------------------------------------------------------------------------------------------------------ 13

6.2 Processing of QECAs ------------------------------------------------------------------------------------------------- 13

7.0 QECK REPAIRS (CLINS 0X04, 0X05, 0X06, AND 0X07) -------------------------------- 14

7.1Categorize Repair ------------------------------------------------------------------------------------------------------ 14

7.2 Repair -------------------------------------------------------------------------------------------------------------------- 14

7.3 Deviation Requests --------------------------------------------------------------------------------------------------- 14

8.0 CORE ENGINE REPAIR (CLINS 0X08, 0X09, 0X10, AND 0X11) ---------------------- 14

9.0 PROPELLER GEARBOX AND GEARBOX MOUNTED ACCESSORY DRIVE REPAIR

(CLINS 0X12 AND 0X13) -------------------------------------------------------------------------------- 15

10.0 ADDITIONAL REPAIRS (CLINS 0X14, 0X15, 0X16, AND 0X17) ------------------- 15

APPENDIX A: KC-130J QUICK ENGINE CHANGE ASSEMBLY (QECA) SYSTEM

DESCRIPTION ---------------------------------------------------------------------------------------------- 17

APPENDIX B: PROJECTED UTILIZATION RATES ---------------------------------------------- 19

APPENDIX C: METRICS -------------------------------------------------------------------------------- 20

1. METRIC INTRODUCTION --------------------------------------------------------------------------- 20

2. METRIC DEFINITIONS ------------------------------------------------------------------------------- 20

APPENDIX D: REPAIR PROCESSES ----------------------------------------------------------------- 22

1.0 RECEIPT AND PROCESSING ----------------------------------------------------------------------------------------- 22

2.0 QECA REPAIRS - INDUCTION --------------------------------------------------------------------------------------- 22

4.0 CORE ENGINE TEARDOWNS ---------------------------------------------------------------------------------------- 23

APPENDIX E: LIST OF ACRONYMS ---------------------------------------------------------------- 24

PWS REVISION HISTORY

Original Draft…………………………………………………………………………………… 20 January 2015

1.0 SCOPE

This Performance Work Statement (PWS) defines the effort required for the Contractor to provide depot-level repair of KC-130J Quick Engine Change Assemblies (QECA) for the Naval Air Systems Command (NAVAIR) KC-130J aircraft utilized by the U.S. Marine Corps (USMC), U.S. Navy (USN), and NAVAIR-managed Foreign Military Sales (FMS) cases.

1.1 Weapon System Description and Use

The KC-130J aircraft performs USMC, USN, and Kuwait Air Force (KAF) peculiar mission requirements such as in-flight refueling for fixed and rotary wing aircraft, rapid ground refueling, and other tactical capabilities. The KC- 130J aircraft QECA consists of the Rolls-Royce AE2100D3 turboprop engine and the Lockheed Martin Quick Engine Change Kit (QECK). Additional descriptions of the propulsion system are outlined in Appendix A, KC- 130J Quick Engine Change Assembly (QECA) System Description.

1.2 Support Concept

This PWS details the QECA depot repair requirements and engineering and technical services required to meet the operational concept, maintenance concept, and support dates as defined herein with the repair capability meeting the Government’s annual engine operating hours outlined in Appendix B, Projected Utilization Rates. The Government manages engines as a propulsion package referred to as a “QECA,” which is comprised of the nacelle (QECK), core engine, and the necessary components attached to them in order to make the QECA a complete operational unit. As such, the Government will ship complete QECAs to the Contractor’s depot maintenance center for repair. Propeller Gearbox (PGB) and Gearbox Mounted Accessory Drive (GMAD) will also be shipped as individual components for repair. Attachment 2, Engine Inventory to the contract provides a list of all QECK and engines currently managed in the NAVAIR inventory and expected to be repaired by the Contractor under this PWS.

As the Government continues to procure aircraft and spare engines, this attachment will be updated as additions and deletions are made to the inventory.

1.2.1 Operational Concept

The Government operates the KC-130J at sites within the continental United States and outside the continental United States. The sites are identified in Appendix B, Projected Utilization Rates.

1.2.2 Maintenance Concept

Government, FMS, and Government-contracted personnel maintain the propulsion system at the organizational-level (O-level) in accordance with the approved maintenance concept as described in the NAVAIR KC-130J Organizational Maintenance Manuals, KAF KC-130J Organizational Maintenance Manuals, NAVAIR Technical Directives (TDs), Naval Aviation Maintenance Program (NAMP), and other Government approved data. This support includes servicing, troubleshooting, scheduled and unscheduled maintenance actions, and preservation and packing of retrograde material. The Contractor is responsible for facilities, labor, parts, material, and test equipment for depot-level repair of QECAs. The Contractor is responsible for effectively managing repair part inventories, including forecasting of all material requirements and vendor contracts resulting in all received material being returned to ready-for-issue (RFI) status.

2.0 APPLICABLE DOCUMENTS

These documents are for reference purposes only. Specific requirements are identified in the applicable PWS sections.

2.1 Government Documents

• NAVAIR KC-130J Organizational Maintenance Manuals

• COMNAVAIRFORINST 4790.2B,The Naval Aviation Maintenance Program (NAMP)

• NAVAIRINST 13700.15F, Decision Knowledge Programming for Logistics Analysis and Technical

Evaluation (DECKPLATE) Engine/Propulsion System Module Management

• Department of Defense (DoD) Manual 5220.22-M, National Industrial Security Program Operating Manual

(NISPOM)

• NAVAIRINST 4130.1D, Naval Air Systems Command Configuration Management Process

• MIL-HDBK-516, Airworthiness Certification Criteria

• JSSG-2007 Joint Services Specification Guide – Engines, Aircraft, Turbine

• SECNAVINST 4140.2 Management of Aviation Critical Safety Items

• NAVAIRINST 13100.15, Engineering Technical Review of Commercial-Derivative Aircraft Programs

• National Aerospace Standard (NAS) 411 Hazardous Materials Management Program

• Title 14 CFR Part 21, Certification Procedures for Products and Parts

• Title 14 CFR Part 39, Airworthiness Directives

• Title 14 CFR Part 145, Repair Station Requirements (European Aviation Safety Agency (EASA) Part 145 certified Repair Station is an acceptable equivalent to 14 CFR Part 145)

• NAVAIRINST 00-25-300, NAVAIR Technical Directives System

• DoD 4160.21-M, Defense Materiel Disposition Manual

• DoD 4160.28, Defense Demilitarization: Program Administration

• DoD 8570.01-M, Information Assurance Workforce Improvement Program

• NAVAIR 01-75GAJ-6 Periodic Maintenance Information Manual (PMIC)

2.2 Kuwait Air Force Specific Documents

• KAF KC-130J Organizational Maintenance Manuals

• Kuwait Aviation Maintenance Program 4790.2B

2.3 Other Documents

• OEM Repair Manuals

3.0 GENERAL REQUIREMENTS

This section establishes the requirements for the Contractor to execute this PWS. These requirements apply to all contract line item numbers (CLINs). The Contractor shall use best commercial practices unless otherwise specified.

The Contractor shall meet the metrics defined in Appendix C, Metrics.

3.1 Quality Management System

The Contractor’s project management efforts shall satisfy the requirements of this PWS. The Contractor shall provide and use a commercial quality system that demonstrates a systems approach for managing quality, safety, and its compliance with all contractual requirements in accordance with Title 14 CFR Part 145. The Contractor is accountable for all sub-contractors and vendors, and as such, shall be required to implement a quality system achieving control of the quality of the services and supplies. The Government reserves the right to perform any necessary inspections, verifications, and evaluations to the Contractor’s repair facilities at any time during contract performance to ascertain the adequacy of the quality system.

3.2 Operations Security

The Contractor shall establish and maintain a security program with policies and procedures that are in compliance with the requirements of the National Industrial Security Program Operating Manual (NISPOM) DODM 5220.22- M.

3.3 Project Management

3.3.1 Project and Risk Management. The Contractor shall provide project management to meet the performance requirements of the PWS. The Contractor shall establish and maintain a risk management program for the purpose of early identification and mitigation of program risks as to not negatively impact contract performance.

3.3.2 Project Manager. The Contractor shall designate a single point of contact responsible for the overall management and performance of the contract requirements. The Contractor shall provide, in writing, the name and contact information of the designee to the Procurement Contract Officer (PCO) within ten working days of contract award. Any change of Project Manager shall be submitted to the PCO within five business days.

3.4 Hazardous Material and Waste

The Contractor shall implement hazardous material handling procedures that comply with local, state, and federal laws, and regulations concerning the use of Class I Ozone Depleting Compounds and Ozone Depleting Substances identified in NAS411-1.

3.5 Package, Handling, Shipping, and Transportation

3.5.1 Contractor Shipping Requirements QECAs and Components. The Contractor shall coordinate and ship QECAs and components as directed by the Contracting Officer’s Representative (COR). Transportation costs of the QECAs between the Government site and the Contractor’s facility are the responsibility of the Government and will be chargeable to the assigned Transportation Account Codes (TAC), as provided in Section G of the contract. The Contractor is responsible for all other transportations and shipments.

3.5.2 Shipping, Packaging, Storage, and Containers. The Contractor shall preserve and package for transport all Government property in accordance with the OEM Repair Manuals. The primary method for shipping engines and components will be as part of QECAs. Components shall be shipped to and from the Contractor in approved shipping containers. In the event engines are shipped for repair on Government engine stands, the Contractor shall ensure Government engine stands and adapters are fully accounted for and returned to the Government in RFI condition.

3.5.3 Government Furnished Property Shipping. The Contractor shall ship all Government Furnished Property at the request of the COR.

3.6 Export Control Licenses

The Contractor shall have export licenses for all components, parts, and materials that are International Traffic in Arms Regulation controlled no later than 30 days after contract award.

3.7 Engine Transaction Reporting

The Contractor shall comply with the Engine/Propulsion System Module (E/PSM) reporting procedures in accordance with NAVAIRINST 13700.15F as changes in custody, status, or conditions occur. The Government will authorize the Contractor access to the Decision Knowledge Programming for Logistics Analysis and Technical Evaluation (DECKPLATE) Engine Management database.

3.8 Information Assurance

The Contractor shall ensure that personnel accessing information systems have the proper and current Information Assurance (IA) certification to perform IA functions in accordance with DoD 8570.01-M, Information Assurance Workforce Improvement Program. The Contractor shall meet the applicable IA certification requirements to include:

• DoD-approved IA workforce certifications appropriate for each category and level as listed in the current version of DoD 8570.01-M; and appropriate operating system certification for IA technical positions as required by DoD 8570.01-M.

• Documentation validating the IA certification status of personnel performing IA functions.

Contractor personnel who do not have proper and current certifications will be denied access to DOD information systems for the purpose of performing IA functions. The Department of the Navy no longer permits assignment of non-U.S. citizen contractor personnel to IT-II designated positions. Requests to waive the U.S. citizenship requirements for designated IT-II positions may be submitted through the Government Command Security Manager to the Deputy Under Secretary of the Navy for Plans, Policy, Oversight, and Integration. Failure to provide necessary security and IT documentation in a timely manner will prevent proper in-processing and system access for the employee prior to their reporting date.

4.0 PROJECT REQUIREMENTS (CLINs 0X01 and 0X02)

4.1 Management Plan

The Contractor shall create and maintain a Management Plan to provide processes for providing project management, QECA and component repair, and engineering and technical services required under this PWS. The Contractor shall submit the Management Plan in accordance with Contract Data Requirements Lists (CDRLs) A001, AA01, AB01, AC01, and AD01.

4.2 Meetings and Reviews

4.2.1 Post-Award Conference. The Contractor shall host a post-award conference at the Contractor’s facility, with the Government no later than 45 days after contract award. This meeting will cover the topics as set forth in FAR Subpart 42.5, Post-award Orientation. Additionally, the Contractor shall demonstrate its management procedures, provide progress assessments, review technical and other specialty area status, and schedule dates for near-term critical meetings and actions.

4.2.2 Project Manager. The Contractor’s Project Manager shall attend and participate in the meetings listed below.

Meetings will be scheduled by the Government with at least 30 days advance notice.

4.2.2.1 The Contractor shall host semi-annual Program Management Reviews (PMRs) at the Contractor’s facility.

4.2.2.2 The Contractor shall provide weekly status reports to the COR of all QECAs at the depot via weekly teleconference.

4.2.2.3 The Contractor shall host and conduct monthly meetings by telephone or video teleconference to provide status on all open actions, performance metrics status, engine status highlights, engineering and logistical emergent issues, risks, the potential impacts, and mitigation approaches.

4.2.3 Agenda. The Contractor shall prepare an Agenda for the PMRs and submit the Agenda in accordance with CDRLs A002, AA02, AB02, AC02, and AD02.

4.2.4 Meeting Minutes. The Contractor shall prepare Meeting Minutes for the PMR and submit the Meeting Minutes in accordance with CDRLs A003, AA03, AB03, AC03, and AD03.

4.2.5 Government-Furnished Equipment. Spare core engines will be provided as Government Furnished Equipment (GFE) in accordance with Attachment 2 to the contract. These GFE items will be utilized only when authorized by the COR. The Contractor shall store the USMC or FMS owned spare core engines and shipping containers in a secure storage area. The Contractor shall utilize OEM methods and procedures for maintaining the engines in a preserved and ready-for-installation state and will provide status of all GFE items during monthly meetings. The monthly preservation task shall include:

a) Perform general container maintenance

b) Ensure cleanliness and legible stenciling

c) Ensure all fasteners are in place and properly torque

d) Inspect for damage to the outer surface of the container

e) Examine the external shock sensors

f) Monitor humidity

g) Reclamation of atmosphere (as needed)

h) The Contractor shall maintain preservation documentation

4.3 Airworthiness and Configuration Management

4.3.1 Airworthiness Certification Authority. NAVAIR is the airworthiness certification authority for the KC- 130J aircraft. NAVAIR’s airworthiness certification for KC-130J propulsion system leverages the Federal Aviation Administration (FAA) type certification and civil airworthiness standards as a baseline in accordance with MIL- HNDBK-516, JSSG-2007, and NAVAIRINST 13100.15. The current depot maintenance manuals, illustrated parts breakdown, and formal TDs form the baseline certification for airworthiness of depot-repaired engines.

4.3.2 Configuration Changes. The Contractor shall review the engine logbooks for formal NAVAIR TDs requiring incorporation during repair and document the incorporation of the TD upon incorporation. Applicable AE2100 TDs are available for download from the Naval Aviation Technical and Engineering Services Command’s (NATEC) website www.natec.navy.mil.

4.3.3 Technical Variances and Deviations. The Contractor shall request in writing NAVAIR approval via the COR for any recommended changes to repaired engines or components involving repair procedures, repair limits, and repair Technical Variance (TV) activity to all AE2100D3 engines repaired under this PWS. A TV is defined as any deviation or variance that is outside the approved configuration, tolerances, or limits defined in the OEM repair manuals. Additionally, the Contractor shall make available all relevant data, analysis, and assumptions for review by NAVAIR technical authority experts to document the nature of the change to support, why the change is needed, what testing was completed to ensure safety, and if the change is permanent or temporary. NAVAIR will provide disposition within three working days.

4.4 ENGINEERING AND TECHNICAL SERVICES

4.4.1 Technical Services

The Contractor shall provide at the request of the Government and with COR approval, engineering and technical support defined below. These tasks include the following:

4.4.1.1 Engineering Investigations. The Contractor shall support Engineering Investigations (EIs) of items designated special interest items by NAVAIR. The Fleet Support Team (FST) engineering personnel will coordinate with the Contractor on the induction of EI or Product Quality Deficiency Report (PQDR) items and provide specific disassembly, inspection, and data recording instructions. Disposition instructions and release of the EI or PQDR item will be provided by FST engineering upon completion of the EI. The time required to support the EI shall not be counted against the Contractor’s Turn-around Time requirement as outlined in Appendix C.

4.4.1.2 Engineering Analysis. The Contractor shall conduct engineering analysis and provide solutions to problems relating to the depot-level repair of QECA.

4.4.1.3 Trending Deficiencies. The Contractor shall track trends of in-service deficiencies experienced by AE2100D3 engines.

4.4.1.4 Component History. The Contractor shall research component history.

5.0 GENERAL REPAIR REQUIREMENTS

5.1 Repairs

The following requirements shall apply to all repairs performed under sections 6 through 10 of this PWS:

5.1.1 QECA Repairs. The Contractor shall perform all unscheduled and scheduled repairs, maintenance actions, restoration, test, required OEM Service Bulletins, FAA-approved airworthiness directives in accordance with Title 14 CFR Part 39, and NAVAIR TDs that are beyond O-level on all QECAs in accordance with approved Government and OEM maintenance manuals.

5.1.2 Repair Materials. The Contractor shall ensure the safety and quality of all materials used in repairs, and ensure that all new, repaired, or refurbished parts are FAA-certified in accordance with Title 14 CFR Part 21 and accompanied by FAA Form 8130-3, Authorized Release Certificate, or other documentation for return-to-service (e.g., Canada Form 1, or European Aviation Safety Agency Form 1 tag), a copy of the work order, and the FAA Form 8110-3 Statement of Compliance with Airworthiness Standards.

5.1.3 Perform Repairs. The Contractor shall provide all labor, parts, and material necessary to perform repairs.

5.1.4 Technical Variances and Deviations. The Contractor shall request in writing NAVAIR approval via the COR for any proposed Technical Variances (TV) and/or deviations from established repair procedures or material condition limits to all AE2100D3 engines repaired under this PWS. A TV is defined as any deviation or variance that is outside the approved configuration, tolerances, or limits defined in the OEM repair manuals. Additionally, the Contractor shall make available all relevant data, analysis, and assumptions for review by NAVAIR technical authority experts to document the nature of the change to support, why the change is needed, what testing was completed to ensure safety, and if the change is permanent or temporary. NAVAIR will provide disposition within three working days.

5.1.5 Work Performed Records. The Contractor shall provide documentation to certify all work was accomplished in accordance with Federal Aviation Regulation Part 145, Repair Stations, and in accordance with current policies and procedures; and record all maintenance, modifications, and component life information into the applicable NAVAIR/KAF logbook, commercial logbook, and record for all contractor work performed.

5.1.5.1 The Contractor shall ensure that all work accomplished has been certified as airworthy and properly documented on the FAA Form 8130-3 with a copy of the work order to include any FAA Form 8110-3 or an equivalent Certificate of Release, Test, and Conformity.

5.1.5.2 The Contractor shall provide notification of any issue concerning a CSI part to the COR and

FAA via email within 48 hours.

5.1.6 Engine Disks. The Contractor shall update engine data disks for all work performed by the Contractor.

5.1.7 Reserved

5.1.8 Repair Action Report. The Contractor shall compile all repair data and submit a Repair Action Report on repaired QECAs, engines, modules, and components in accordance with CDRLs A004, AA04, AB04, AC04, and

AD04.

5.1.9 Life Limited Components. The contractor shall replace all life limited components referenced in the KC- 130J Periodic Maintenance Information Manual (PMIC), with less than 800 cycles life remaining per the recorded cycles in Engine Logbook.

5.1.10 Bonded Storage. The Contractor shall, upon Government direction, provide indoor bonded storage for up to two NAVAIR or FMS-owned spare core engines and two shipping containers.

5.1.11 Property Control. Core engines and containers stored at the Contractor’s facility shall be managed under the Contractor’s Government-approved property control system. The Contractor shall keep any property received under this contract separate from other property.

5.1.12 Preservation. The Contractor shall use approved OEM methods and procedures for maintaining the engines in a preserved and RFI state.

5.1.13 Monthly Preservation Tasks. The Contractor shall perform the following monthly preservation tasks:

5.1.13.1 Perform general container maintenance

5.1.13.2 Ensure cleanliness and legible stenciling

5.1.13.3 Ensure all fasteners are in place and properly torqued

5.1.13.4 Inspect for damage to the outer surface of the container

5.1.13.5 Examine the external shock sensors

5.1.13.6 Monitor humidity

5.1.13.7 Reclamation of atmosphere (as needed)

5.2 Security of Government Property

All property received under this contract shall be in an enclosed and covered area accessible only to authorized personnel and protected against loss, damage, and theft.

5.3 Cannibalization

The Contractor shall request, in writing, approval from the COR to cannibalize parts, components, or modules from other QECAs. Cannibalization approval by the Government shall not constitute grounds to extend the turn-around time of the QECA from which the parts were cannibalized.

5.4 Condemnation

Parts, components, and modules shall be considered for condemnation if their repair exceeds the repairable limits specified in the applicable OEM manuals. The Contractor shall not repair condemned parts unless authorized in writing by the COR. All condemned parts shall be reported in the Master Repair Document and the Contractor shall request the Government provide disposition guidance for all condemned parts. The Government may choose to recycle some or all of unusable materials.

5.5 Disposition of Material

The Contractor shall include in its NAVAIR approved Management Plan the process for disposal of Government property and shall include the requirements stipulated in the FAR Part 45, Government Property; DoD 4160.21-M, Defense Material Disposition Manual; and DoD 4160.28, Defense Demilitarization: Program Administration. The Contractor shall dispose of all removed Government property in accordance with the Management Plan.

6.0 INDUCTION, DISASSEMBLY, AND ASSEMBLY OF THE QECA

(CLIN 0X03)

6.1 Receipt of QECAs

The Contractor shall receive and induct all QECAs that have identified discrepancies requiring partial or full disassembly.

6.1.1 Receiving Inspections. The Contractor shall perform a receiving inspection of the QECA and notify the COR of findings within three days of receipt at the Contractor’s facility.

6.1.2 Engine Transaction Reports. The Contractor shall submit Engine Transaction Reports (ETR) via DECKPLATE Engine Management on all engines or components in accordance with NAVAIRINST 13700.15E.

Lost or missing maintenance records shall not prevent the reporting of receipt of engines or components in DECKPLATE. In the case of lost or missing maintenance records, the ETR entries shall identify what records were not received.

6.1.3 Records Protection. The Contractor shall protect all maintenance records from damage or loss.

6.2 Processing of QECAs

The Contractor shall perform receiving, inspection, removal of core engine, minor repair of QECK, reinstallation of the core engine, final inspections, report preparations, and logbook and record card update actions to return the QECA to RFI condition as outlined in Appendix D, Repair Processes.

7.0 QECK REPAIRS (CLINs 0X04, 0X05, 0X06, and 0X07)

A QECK depot-level repair encompasses the structural components, all attaching components, wiring, ducts, and tubing of the QECA that are not part of the core engine. The QECK repairs shall be classified, as outlined below, based on the number of flight hours acquired since the last depot shop visit. Flight hours are defined as the amount of hours on the QECK since the last shop visit, as recorded by the Government in NAVFLIR.

7.1Categorize Repair The categories of repair are defined as follows:

• CLIN 0X04 - Category 1 Repair: 0-1,500 hours since last shop visit

• CLIN 0X05 - Category 2 Repair: 1,501 – 3,000 hours since last shop visit

• CLIN 0X06 - Category 3 Repair: 3,001 – 4,500 hours since last shop visit

• CLIN 0X07 - Category 4 Repair: 4,501 or more hours since last shop visit

7.2 Repair

Upon receipt of executed Task Order, the Contractor shall repair the QECK.

7.3 Deviation Requests

The Contractor shall obtain in writing NAVAIR approval via the COR for any change to or deviation from QECK and subcomponents of the QECK prescribed repair procedure or test specification(s) in approved OEM and Government Maintenance manuals. NAVAIR will provide disposition within five working days.

8.0 CORE ENGINE REPAIR (CLINs 0X08, 0X09, 0X10, and 0X11)

Modules are defined below and are inclusive of all attaching components, wiring harnesses, tubing, and ducting.

Repairs are inclusive of all disassembly, inspections, repairs, component testing, reassembly of Power Section and Torquemeter, and operational testing of the core engine. The engine repairs shall be classified, as outlined below, based on the number of flight hours acquired since the last depot shop visit. Flight hours are defined as the amount of hours on the engine since the last shop visit, as recorded by the Government in NAVFLIR.

• Torquemeter Assembly

• Compressor and Power Unit Accessory Drive

• Hot Section o Compressor Diffuser o Combustor o Turbine

8.1 Categorize Repair

The categories of repair are defined as follows:

• CLIN 0X08 - Category 1 Repair: 0-1,500 hours since last shop visit

• CLIN 0X09 - Category 2 Repair: 1,501 – 3,000 hours since last shop visit

• CLIN 0X10 - Category 3 Repair: 3,001 – 4,500 hours since last shop visit

• CLIN 0X11 - Category 4 Repair: 4,501 or more hours since last shop visit

8.2 Repair

Upon receipt of executed Task Order, the Contractor shall repair the engine.

8.3 Reassemble

Upon repair of the module(s), the Contractor shall reassemble the Power Section and Torquemeter.

8.4 Operational Test

Upon reassembly of a core engine, the Contractor shall perform an operational test of the engine to certify as RFI.

All engines repaired by the Contractor shall have a minimum of one hundred percent (100%) rated power in order to be considered RFI unless otherwise approved by the Government.

9.0 PROPELLER GEARBOX AND GEARBOX MOUNTED ACCESSORY

DRIVE REPAIR (CLINs 0X12 and 0X13)

This section applies to the AE2100D3 PGB and GMAD units that are received by the Contractor either installed in a QECA or as stand-alone units. The PGB and GMAD repairs shall be classified, as outlined below, based on the number of flight hours acquired since the last depot shop visit. Flight hours are defined as the amount of hours on the PGB and GMAD since the last shop visit, as recorded by the Government in NAVFLIR.

9.1 Categorize Repair

• The categories of repair are defined as follows:

o CLIN 0X12 – Category 1 Repair: 0-2,000 hours since last shop visit o CLIN 0X13 – Category 2 Repair: 2,001– or more hours since last shop visit

9.2 Repair

Upon receipt of executed Task Order, the Contractor shall repair the PGB and GMAD.

9.3 Operational Test

Upon repair of the PGB and GMAD, the Contractor shall perform operational test of the units to certify as RFI.

9.3.1 For PGB and GMAD units received installed, the operational test should be accomplished once installed on the core engine.

9.3.2 For PGB and GMAD units received as standalone assets, the test may be completed using a standalone test platform or as an installed unit on a core engine.

9.4 Request Disposition

Upon successful completion of operational test, the Contractor shall request Government disposition from the COR for the PGB and GMAD.

10.0 ADDITIONAL REPAIRS (CLINs 0X14, 0X15, 0X16, and 0X17)

The Contractor shall perform repairs under this section in conjunction with the repairs listed in Sections 7 and 8 of this PWS. The intent of this section is to provide for repairs considered beyond the scope of sections 7 and 8 of this PWS. All additional repairs shall be accomplished using the same process outlined in all repair sections of the PWS.

Additional repairs are:

10.1 External Foreign Object Debris (FOD) events (CLIN 0X14). The Contractor shall repair engines with external FOD damage (such as bird strikes/ingestion and other external debris) under this CLIN.

10.2 Radiological Control (RADCON) QECA Survey (CLIN 0X15). Under this CLIN, the Contractor shall disassemble, survey, inspect, and decontaminate a radiation contaminated QECA IAW contract Attachment 3 AE2100 RADCON Engine Teardown Inspection Plan complying with all local laws and regulations, and the following:

a) The Contractor shall make the radiological survey facility available for Government site survey within 30 days of contract award.

b) The Contractor shall perform up to three decontamination attempts if the component is found above the limits. If there is less than a 10% reduction in radioactivity between the initial survey and the first decontamination attempt, and the component remains above limits, the item shall be quarantined. If the component remains above limits after the third decontamination attempt, the component shall be quarantined.

c) The Contractor shall retain all quarantined components at the radiological survey facility until the Government provides disposition instructions.

d) The Contractor shall complete and submit all Survey Plan Appendices and associated documentation completely, correctly, and within the guidelines provided in the survey plan. The Contractor shall submit the appendices for each QECA survey as each appendix is completed.

e) The Contractor shall retain all QECAs at the radiological survey facility until the component is cleared for release.

All QECAs surveyed under this CLIN will be reviewed and cleared by the Government prior to release for reassembly. This release shall be provided by the Government via Naval message. The Contractor shall perform reassembly of the QECA under CLIN 0X16 or 0X17 as appropriate.

10.3 Engine Reassembly (CLIN 0X16). Under this CLIN, the Contractor shall inspect and reassemble an engine received in a disassembled state. These engines were disassembled under a separate contract during RADCON survey and have been cleared for reassembly by NAVSEA. The Contractor shall perform the reassembly under this CLIN concurrently with the repair procedures performed under one of the following CLINs: 0X08, 0X09, and 0X10, as outlined in Section 8 of this PWS. The Contractor shall perform all repairs necessary to restore the engine to RFI condition.

10.4 QECK Reassembly (CLIN 0X17). Under this CLIN, the Contractor shall inspect and reassemble a QECK received in a disassembled state. These QECKs were disassembled under a separate contract during RADCON survey and have been cleared for reassembly by NAVSEA. The Contractor shall perform the reassembly under this CLIN concurrently with the repair procedures performed under one of the following CLINs: 0X04, 0X05, and 0X06, as outlined in Section 7 of this PWS. The Contractor shall perform all repairs necessary to restore the QECK to RFI condition.

APPENDIX A: KC-130J QUICK ENGINE CHANGE ASSEMBLY (QECA)

SYSTEM DESCRIPTION

QECA SYSTEM DESCRIPTION

The KC-130J propulsion system is comprised of the AE2100D3 turboprop engine manufactured by Rolls-Royce and the nacelle (commonly referred to as “QECK”) assembly manufactured by Lockheed Martin. The QECA is maintained as a complete ready to install and operate assembly.

AE2100D3 TURBOPROP ENGINE DESCRIPTION

The Rolls-Royce AE2100D3 engine is comprised of five major modules:

1. Power Section

2. Torque meter

3. Power Unit Accessory Drive

4. Gearbox Mounted Accessory Drive

5. Propeller Gearbox (PGB)

Each engine includes the below listed major components and Line Replaceable Units LRU):

1. Starter 11. Starter control valve 21. Torquemeter pick-ups

2. Compressor inlet pressure sensors

12. Compressor inlet temperature sensors

22. Thermocouples

3. Full authority digital electronic control

(FADEC) (2)

13. Indicating magnetic plugs 23. Fuel pump metering unit

4. Compressor variable geometry actuator

14. Anti-ice valve 24. Permanent magnetic alternator

5. Igniters 15. Ignition exciters 25. Fuel cooled oil cooler

6. NP harness 16. NP speed sensor 26. Power Section lube and scavenge pump

7. Fuel nozzles 17. NG speed sensors 27. PGB lube and scavenge pump

8. Bleed control valve 18. All engine tubing 28. Prop shaft flange adapter

9. FADEC A harness 19. FADEC B harness 29. Compressor bleed valves

10. EMS harness 20. Fuel flow meter

KC-130J NACELLE DESCRIPTION

The Lockheed Martin KC-130J Nacelle is comprised of the following:

1. Nacelle structure 8. Engine and aircraft pneumatic system

2. Engine mounts 9. Engine and aircraft electrical system

3. Electric generator 10. Engine fuel system

4. Propeller pitch control unit 11. Engine control and indicating systems

5. Propeller over-speed governor 12. Engine oil system

6. Engine exhaust nozzle 13. Engine starting system

7. Brush block and bracket 14. Engine hydraulic system

The above lists are intended to detail only the major modules and components of the engine; they are not all-inclusive. A thorough breakdown of the engine that includes all parts, repairable as well as consumable, can be found in the Rolls-Royce AE2100D3 Illustrated Parts Catalog or the NAVAIR KC-130J Organizational Maintenance Manuals.

APPENDIX B: PROJECTED UTILIZATION RATES

Projected KC-130J Distribution by Site and Projected Flight Hours:

USMC and USN Activities FY17 FY18 FY19 FY20 FY21 Active Squadron VMGR-152 / Iwakuni Japan 15 15 15 15 15 VMGR-252 / Cherry Point, NC 15 15 15 15 15 VMGR-352 / Miramar, CA 15 15 15 15 15 Projected Active Aircraft Flight Hours 20,993 21,563 20,758 21,021 20,246

Reserve Squadron

VMGR-452 / TBD 0 0 0 2 5

VMGR-234 / Fort Worth, TX 7 8 10 12 12 Projected Reserve Aircraft Flight Hours 2,500 2,500 2,500 2,500 5,200

Test Squadron VX-20 / Patuxent River, MD 1 1 1 1 1 Projected Test Aircraft Flight Hours 120 120 120 120 120

Total Aircraft USMC and USN 53 54 57 60 62 FMS Activities Kuwait (KAF) 3 3 3 3 3 Projected Total Aircraft Flight Hours 1,500 1,500 1,500 1,500 1,500

Projected KC-130J Surge Flight Hours:

• USMC estimated combat utilization rate of 90 hour per aircraft per month

• KAF estimated combat utilization rate of 13 hour per aircraft per month

APPENDIX C: METRICS

1. METRIC INTRODUCTION

1.1 This Appendix defines the metrics selected to measure the Contractor’s performance effectiveness in meeting the requirements established in the Performance Work Statement. The Contractor shall be held responsible for meeting established metrics in accordance with clause H-1 Liquidated Damages and any other remedies available under this contract. These metrics were selected in order to institute a program that provides Government operating forces with the QECA readiness necessary to meet their worldwide national security commitments.

1.2 Throughout the contract period, Contractor performance to metrics will be continually monitored per the Quality Assurance Surveillance Plan (QASP). Formal reviews of performance will be held at each Program Management Review. At each review (semi-annually) the cause and corrective actions associated with non-performance to metrics will be discussed and addressed.

1.3 In cases of non-performance to metrics, the following causes and results will be addressed by the NAVAIR and Contractor program management group.

• Validity of metric and measurements or data feeding the metric

• Impact on fleet readiness and operation due to the metric infraction or non-attainment

• Reason or cause for the metric infraction; both Government-caused and Contractor-caused

• Corrective action taken and results (metric performance due to timing associated with corrective action implementation)

1.4 The Metrics for performance monitoring and management are:

Metric Name Metric

QECA Repair Turn-Around Time (TAT) 100 Days PGB and GMAD TAT (Stand Alone) RADCON Survey TAT

45 Days 90 Days

2. METRIC DEFINITIONS

2.1 QECA REPAIR TURN-AROUND TIME

The QECA Repair TAT conveys the Government’s requirements for repair responsiveness. The Contractor can use this metric to help determine the proper capacity of its repair facilities, repair part inventories, and subcontract requirements. The TAT starts once the Government issues a task order for repair of a QECA and the Contractor receives the QECA. TAT ends when the Contractor provides copies of repair documentation and notifies the COR that the QECA is RFI and ready for shipment.

Date RFI – Date task order issued and QECA received = Total Days TAT

2.2 PGB and GMAD TURN-AROUND TIME

The PGB and GMAD TAT convey the Government’s requirements for repair responsiveness. The Contractor can use this metric to help determine the proper capacity of its repair facilities, repair part inventories, and subcontract requirements. The TAT starts once the Government issues a task order for repair of a specific module and the Contractor receives the specific module. TAT ends when the Contractor provides copies of repair documentation and notifies the COR that the module is RFI and ready for shipment.

Date RFI – Date task order issued and PGB received = Total Days TAT

2.3 RADCON SURVEY TURN-AROUND TIME

The RADCON Survey TAT conveys the Government’s requirements for survey responsiveness. The Contractor can use this metric to help determine the proper capacity of its radiological survey facility. The TAT starts once the Government issues a task order for survey of a QECA and the Contractor receives the QECA. TAT ends when the Government authorizes the QECA for release or disposition.

Date the Government authorizes the QECA for release or disposition – Date task order issued and QECA received = Total Days TAT

APPENDIX D: REPAIR PROCESSES

1.0 RECEIPT AND PROCESSING

1.1 The COR will notify the Contractor of inbound QECAs and standalone components.

1.2. The Contractor shall notify the COR upon receipt of the QECA and provide notification of any visible damage.

1.3 The COR will provide authorization for induction of the QECA or standalone components.

2.0 QECA REPAIRS - INDUCTION

2.1 The Contractor shall inspect the QECA for damage and missing components, review associated log books for completeness, and notify the COR of the “As Received Condition” within five working days of induction. Log books and maintenance records shall be inspected to ensure accurate reporting of serial number information and completeness of each record in accordance with COMNAVAIRFORINST 4790.2. If the serial number on the maintenance record is not the same as the item received, or if records are missing or deficient, the Contractor shall notify the COR.

2.2 The COR will acknowledge the “As Received Condition” report and provide any special requirements for testing or disassembly related to a Deficiency Report or Engineering Investigation within five working days.

2.3 The Contractor shall perform the following:

a) Remove core engine from QECA.

b) Perform detailed inspection of the QECK.

c) Complete minor QECK repairs defined as follows:

1) Replacement of hardware needed for engine removal and reinstallation

2) Realignment and/or replacement of common AN/AS/MS/M part numbered clamps nuts and bolts for harnesses, tubing and ducting

3) Minor corrosion touch-up, i.e. surface cleaning and treatment

d) Upon repair of core engine and QECK, reinstall engine into QECK

e) Complete post-engine installation inspections for RFI certification of QECA

f) Preserve QECA for storage.

g) Install QECA on transportation stand and secure environmental bag.

h) Update engine, QECK, or component logbook and/or records.

i) Prepare applicable repair reports.

j) Upon completion of the subject repair, the Contractor shall provide a copy of the repair report, Test acceptance data, and DD 250 to the COR.

k) Upon receipt of the repair report and CoC, the COR will provide shipping destination to the Contractor.

l) The Contractor shall arrange for transportation of the QECA to the destination provided by the COR.

m) The Contractor shall compile all repair data and submit a Repair Action Report in accordance with the PWS.

4.0 CORE ENGINE TEARDOWNS

The Contractor and the COR will review applicable reason for removal data, induction findings, and any special testing or disassembly requirements associated with an investigation or deficiency report and perform repairs in accordance with the applicable CLIN as defined in this PWS.

N00019-15-R-0016

20 January 2016

APPENDIX E: LIST OF ACRONYMS

ASTM American Society for Testing and Materials CDRL Contract Data Requirements List CLIN Contract Line Item Number CoC Certificate of Conformance COR Contracting Officer’s Representative DECKPLATE Decision Knowledge Programming for Logistics

Analysis and Technical Evaluation D-level Depot-level DoD Department of Defense EI Engineering Investigation ETR Engine Transaction Report FAA Federal Aviation Administration FAR Federal Acquisition Regulation FMS Foreign Military Sales GFE Government-furnished Equipment GFP Government-furnished Property GMAD Gearbox Mounted Accessory Drive IPT Integrated Product Team JTR Joint Travel Regulations KAF Kuwait Air Force MELR Maintenance Engineering Logistics Review NAMP Naval Aviation Maintenance Program NAVAIR Naval Air Systems Command NISPOM National Industry Security Program Operating Manual OEM Original Equipment Manufacturer O-level Organizational-level PCO Procurement Contracting Officer PGB Propeller Gearbox PMR Program Management Review PQDR Problem Quality Deficiency Report PWS Performance Work Statement QECA Quick Engine Change Assembly QECK Quick Engine Change Kit RFI Ready for Issue TAT Turn-around Time TD Technical Directive TV Technical Variance USG United States Government USMC United States Marine Corps USN United States Navy